Overview / Main Features
The Motorola Surfboard SBV6240 is a DOCSIS 3.0 cable modem that also features an integrated 2-line VoIP telephone adaptor.
Electronically, the Motorola is powered by a TI cable modem chipset and a Zarlink Semiconductor for VoIP applications. The functional front end the SBV6240 features 4 discrete Maxlinear tuner/demodulators that tunes and demodulates the pre-requisit 8 channels of signal (channel bonding technology) spelled out in DOCSIS 3.0. Other DOCSIS 3.0 modem designs we've come across did not require so many tuner/demodulators as those designs tend to have that function integrated into a the core cable modem processing IC.
The SBV6240 also features provisions for internal rechargeable battery as a backup power source in the event of an outage [battery not included in this analysis].
Cable service providers
Pricing - Since most (if not all) cable modem/gateways are provided to consumers by the cable service providers, there is no known market price for these devices.
Availability - North America
For the purposes of this teardown analysis, we have assumed a lifetime production volume of 3M 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 Representing ~60% of total materials cost
Texas Instruments - TNETC4800ZDWG - DOCSIS 3.0 Cable Chipset - Puma 5 Family, Embedded Multimedia Terminal Adapter Applications
Maxlinear - MXL242SF - Tuner / Demodulator - QAM (Qty:4)
Delta Electronics - EADP-24FB - AC Adapter - 14V, 1.7A, 19.6W
Tai Hong Circuit Industrial Co., LTD - 4-Layer - FR4, Lead-Free
Zarlink Semiconductor - Le88276DLC - Telephone Line Interface - Dual-Channel, High Voltage Subscriber Line to uP/DSP Digital Interface
Spansion - S25FL128P0XMFI - Flash - NOR, 128Mb, 104MHz SPI, 3V
Enclosure, Main, Right - Injection Molded ABS-Polycarbonate
Enclosure, Main, Left - Injection Molded ABS-Polycarbonate
Texas Instruments - TPS54325PWP - Regulator - DC-DC Converter, Synchronous Step-Down, 700KHz, 3A, w/ Integrated FET (Qty:2)
Hynix - H5PS5162FFR-Y5C - SDRAM - DDR2, 512Mb, 1.8V
Direct Materials + Manufacturing $55.24
What Is Not Included in our Cost Analysis
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 likely assembled in Taiwan. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were also sourced in Taiwan.
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 Ethernet Jacks), 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 Motorola SBV6240 has an overall component count of 972 (excluding box contents), of which 956 resides on the Main PCB.
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. The cost of manufacturing is also, to some extent, decreased in this case because of assumed labor rate applied for Taiwan.
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.