Overview / Main Features
The Toshiba 42HL167 is a 42 LCD TV with a full HD LCD panel (native 1080p (1920 x 1080 pixel) resolution) from Chi Mei Optoelectronics Corp (Taiwan). Of course, it also supports all HD standards (480i, 480p, 720p, 1080i, and 1080p). Though we cannot gather the exact display specs from the manufacturer's literature, from the LCD panel manufacturer we glean the following display features : 500 nits brightness (20 CCFL backlight), 2000:1 contrast ratio, 16.7 million colors, anti-glare (haze 25%) and hard coatings (3H). Viewing angle is not clearly stated in Chi Mei's documents, though gray to gray average response time 6.5ms. (Toshiba documents state 8ms response time, however).
Furthermore, Toshiba have trademarked a number of Toshiba-specific features that are difficult to reconcile with features offered by other manufacturer's because of the nature of this kind of feature branding. However, some of the more notable features include color temperature control, PixelPure 3G (Toshiba's proprietary digital video processing), DynaLight dynamic backlight control (similar in some ways to recently analyzed white-LED backlighting systems from Samsung which utilize their own proprietary active dimming algorithms and ICs). It is important to note that all TV manufacturer's have their own proprietary ways of tackling image processing and cleanup to improve image quality - and the end results of this feature are very subjective and not covered in detail in our analysis (just the cost of hardware that supports it). Also, the active dimming (DynaLight) controls achieve, per Toshiba a 5x spec improvement over the panel specs. So in this case, presumably, the effective contrast ration should be 10,000:1.
Mid-range LCD TV consumers.
The Toshiba 42HL167 was released in 2007 - no specific dates found, however it appears to have been in Q3, 07.
Pricing and Availability
MSRP $1,699.99 per Toshiba website at time of writing (2/08). However, this model is also available from online e-tailers for as low as ~$1100 at the time of writing.
Availability - The Toshiba 42HL167 is available to the United States market (and presumably others, though possibly under different model names) and readily available at retail electronics stores and online retailers at the time of writing (2/08).
For the purposes of this teardown analysis, we have assumed a lifetime production volume of 100,000 units.
As a reminder, teardown volume production assumptions are primarily used for our cost analysis in terms of amortized NRE and tooling costs, especially for custom components specific to the model being analyzed (mechanical components especially). Unless assumed volumes are different by an order of magnitude, minor changes in volume (say 1 million vs. 2) rarely have a large net effect on our final analysis because of this.
Main Cost Drivers
Chi Mei Optoelectronics - V420H1-L08 - LCD Display Unit - LCS MVA, 42' Diagonal, 1920 x 1080 Pixels (16:9), 0.485mm x 0.485mm Pixel Size, 16.7M Colors, 2000:1 Contrast Ratio, 500cd/m^2 Brightness, 8ms Response Time, Active Area: 930.2mm x 523.3mm - Qty(1)
Toshiba - PE0306 - Power Supply - Qty(1)
Toshiba - PE0307 - Regulator Board - Qty(1)
Electronic Cost Drivers (From Main PCB)
Toshiba Semiconductor - TC90412XBG - Video Processor - Qty(1)
ATI - Theater 312 - VSB/QAM Demodulator - Qty(1)
Daeduck Electronics Co. - Main PCB - 4-Layer - FR4, Lead-Free - Qty(1)
Samsung Semiconductor - K9F5608U0D-P - Flash - NAND, 256Mb (32M x 8) - Qty(1)
Hynix - HY5PS121621C(L)FP - SDRAM - DDR2, 512M (32Mx16), 1.8V, SSTL-18 - Qty(2)
Texas Instruments - TPS54310PWP - Regulator - Synchronous Buck PWM, Adjustable, 3A - Qty(2)
I/O Interface PCB
Panasonic - ENG36E02KF - Tuner Module - Qty(1)
Daeduck Electronics Co. - PCB - 2-Layer - FR4, Lead-Free - Qty(1)
Toshiba Semiconductor - TMP91FY42FG - Microcontroller - 256 Kbytes Flash ROM, 16 Kbytes RAM - Qty(1)
Mechanical Cost Drivers
Enclosure, Main, Rear - Injection Molded Flame Retardant Polystyrene - Qty(1)
Enclosure, Main, Front Bezel - Injection Molded ABS, Silkscreened, Clear Coat, Glossy Black Painted - Qty(1)
PCB Mounting Support - Stamped / Formed Steel, w/ 4 Pin Studs and w/ 36 Threaded Metal Inserts - Qty(1)
Stand Base Support - Die Cast Metal, Black Paint - Qty(1)
Cushion / Bumper - Foam Rubber, Die-Cut, w/PSA - Qty(6)
Materials and Manufacturing $827.74
The total materials and manufacturing costs reported in this analysis reflect ONLY the direct materials cost (from component vendors and assorted EMS providers), AND manufacturing with basic test. Not included in this analysis are costs above and beyond the material manufacture of the core device itself - cost of intellectual property, royalties and licensing fees (those not already included into the per component price), software, software loading and test, shipping, logistics marketing and other channel costs including not only EMS provider and the OEM's margin, but that of other resellers. Our cost analysis is meant to focus on those costs incurred in the manufacture of the core device and exceptionally in some circumstances the packaging and literature as well.
Country of Origin / Volume Assumptions
Based on markings, the unit was assembled in Mexico (which is also the case for Samsung TVs we see in the US). Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were sourced in Mexico as well based on the markings found on the parts. We assumed however, that just as with Samsung, that most of the PCBAs were populated closer to HQ facilities in Japan, then finally integrated into the main enclosure in Mexico. If that is not the case, manufacturing costs would be reduced.
Country of origin assumptions relate directly to the associated cost of manufacturing, where calculated by iSuppli. In the cases of 'finished' sub-assemblies (such as can tuners), we do not calculate internal manufacturing costs, but rather assess the market price of the finished product in which case country of origin assumptions may or may not have a direct effect on pricing.
Remember also that labor rates are applied directly only to hand inserted components and systems in our bill of materials, and although regional assumptions do, these new rates do not have a direct effect on our modeled calculations of placement costs for automated SMD assembly lines. "Auto" inserted components (such as SMT components) placement costs are calculated by an iSuppli algorithm which allocates a cost per component based on the size and pincount of the device. This calculation is affected by country or region of origin as well.
Design for Manufacturing / Device Complexity
The Toshiba 42HL167 LCD TV has a total component count of 1902. This total represents the sum of all discrete components, BUT accounts for the power supply and LCD panel as single items. This total count is comparable to other LCD televisions - such as the Samsung LN-T4061F, and Vizio GV47L both in the 1900 - 2000 range.
Component counts have a direct bearing on the overall manufacturing cycle times and costs, and also can increase or decrease overall yields and re-work. Our calculations of manufacturing costs factor counts and more qualitative complexities in the design. Note that manual labor has a much smaller effect on auto-insertion assembly lines (for the Main PCB, for example), where manufacturing costs are much more capital equipment intensive and driven by these investment costs.
The Toshiba 42HL167 design splits the core functionality and component count between two main PCBs - the 'Main PCB" (as defined in this analysis), or 'motherboard', and the I/O Interface PCB. The Main PCB contains all of the core silicon and functionality (Toshiba Semiconductor - TC90412XBG - Video Processor and the ATI - Theater 312 - VSB/QAM Demodulator), and the I/O controller board contains mostly front-end items, such as the can tuner (Panasonic - ENG36E02KF), but also several other devices such as the Toshiba devices: Microcontroller - TMP91FY42FG and Audio/Video Switch - TB1328FG.
Here is a summary of the major components used in the Toshiba 42HL167 LCD TV design:
Chi Mei Optoelectronics - V420H1-L08 - 42" TFT Liquid Crystal Display module with 20-CCFL Backlight unit and 2ch-LVDS interface.
1920 x 1080 HDTV format
True 16.7M colors (8-bit/color).
Built-in inverter module for backlight
500 nits brightness
2000:1 Contrast Ratio
Gray to gray average 6.5 ms response time
Color saturation (NTSC 86%)
DE (Data Enable) only mode
LVDS (Low Voltage Differential Signaling) interface
Optimized response time for 50/60 Hz frame rate
Ultra wide viewing angle : Super MVA technology
180 degree rotation display option
Video Processor - Toshiba Semiconductor - TC90412XBG
VSB/QAM Demodulator - ATI - Theater 312
I/O & Interface
Texas Instruments - TMDS341A - DVI/HDMI Switch - 3-to-1
ADC - Wolfson Microelectronics - WM8782S - Stereo Audio, 24-Bit, 192kHz
DAC - Texas Instruments - PCM1754DBQ - Stereo Audio, 24-Bit, 192kHz
SDRAM - Hynix - HY5PS121621C(L)FP - DDR2, 512M (32Mx16), 1.8V, SSTL-18
Flash - Samsung Semiconductor - K9F5608U0D-P - NAND, 256Mb (32M x 8)
Flash - SST - SST39VF800A-70-4C-EKE - 8 Mb, Multi-Purpose, 2.7-3.6V, 70ns
I/O Interface PCB
Tuner Module - Panasonic - ENG36E02KF
Microcontroller - Toshiba Semiconductor - TMP91FY42FG - 256 Kbytes Flash ROM, 16 Kbytes RAM
Audio/Video Switch - Toshiba Semiconductor - TB1328FG - S2-Compatible, 8-Input, 2-Output
Audio processor - New Japan Radio - NJW1180A - w/ SRS WOW, & 4-CH Input Selector
Sound Multiplex Demodulator - Panasonic - AN5832SA - SIF Signal, w/ Integrated Voice AGC Circuit
Toshiba - PE0306 - Power Supply
Toshiba - PE0307 - Regulator Board