Set-top Box

Humax PR-HD3000 Set Top Box Teardown

19 July 2011
The following is an overview of a teardown analysis conducted by IHS Benchmarking.

Overview / Main Features

The Humax PR-HD3000 is a HD set top box designed for the BSkyB satellite network in Europe. The Humax set top box features a primarily Broadcom chip solution featuring the BCM7335 A/V Processor and the BCM3445 RF LNA/Splitter at the front end.

Humax PR-HD3000 Set Top Box Main ImageHumax PR-HD3000 Set Top Box Main Image

Target Market

Satellite Operators



Humax PR-HD3000 Set Top Box - Main PCB TopHumax PR-HD3000 Set Top Box - Main PCB Top

Pricing and Availability

Pricing - Typically, set top boxes are not sold directly to consumers but offered as part in parcel of an overall service contract. With that said, we were able to obtain one reference pricing of approximately $180.

Availability - Europe (BSkyB)

Volume Estimations

For the purposes of this teardown analysis, we have applied a lifetime production volume of approximately 500,000 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.

Humax PR-HD3000 Set Top Box Cost AnalysisHumax PR-HD3000 Set Top Box Cost Analysis

Cost Notes

Main Cost Drivers ~70% of Total Materials Cost

Broadcom - BCM7335DPKFEBA1G - Audio / Video Processor - SoC, High Definition PVR Satellite, DVB-S2, 8PSK/QPSK, 405MHz Dual-Threaded MIPS CPU Core, 65nm Process, w/ 1 Integrated Tuner / Demodulator

Ktec(HongKong) Co., Ltd - AC Adapter - 12V, 3.33A, 40W, w/ 3.4ft Cord

Century Circuits Technology - 4-Layer - FR4, Lead-Free

Hynix - H5PS1G63EFR-S6C - SDRAM - DDR2-800, 1Gb, 64Mx16, 1.8V (Qty:2)

Micron Technology - NAND02GW3B2DZA6 - Flash - NAND, SLC, 2Gb, 3.3V

Remote Control Unit

Enclosure, Main, Bottom - Stamped / Formed Electro-Galvanized Steel

Alpha & Omega - AOZ1073AI - Regulator - DC-DC Controller (Qty:4)

Enclosure, Main, Top - Stamped / Formed Electro-Galvanized Steel, Painted

Broadcom - BCM3445KMLGP11 - RF LNA / Splitter

Atmel - ATmega32A-AU - Microcontroller - 8-Bit, 16MHz, 32KB Flash, 1KB ROM, 2KB SRAM, 8-Channel 10-Bit ADC, 32 I/O

Hynix - H5PS5162FFR-S6C - SDRAM - DDR2-800, 512Mb, 32Mx16, 1.8V

Enclosure, Main, Front Panel - Injection Molded ABS, Painted, Printed

Direct Materials + Manufacturing $69.24

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.

Manufacturing Notes

Country of Origin / Volume Assumptions

Based on device markings, we've based our analysis with the final assembly in Eastern Europe. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were also sourced in Eastern Europe.

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 USB connector), 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.

Humax PR-HD3000 Set Top Box - Disassembly View 1Humax PR-HD3000 Set Top Box - Disassembly View 1

Design for Manufacturing / Device Complexity

The Humax PR-HD3000 has an overall component count of 915 parts (excluding box contents). Typically, we see complexity levels for non-DVR set top boxes within the 1000 component +/- 200 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. The cost of manufacturing is also, to some extent, decreased in this case because of assumed labor rate applied for Eastern Europe.

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.

Design Notes

Here is a summary of the major components used in the Humax PR-HD3000 Set top design:

Main PCB

A/V Processing

  • Audio / Video Processor - Broadcom - BCM7335DPKFEBA1G


  • SDRAM - Hynix - H5PS1G63EFR-S6C, DDR2-800, 1Gb, 64Mx16, 1.8V
  • SDRAM - Hynix - H5PS5162FFR-S6C, DDR2-800, 512Mb, 32Mx16, 1.8V
  • Flash - Micron Technology - PC28F320J3D-75, NOR, 32Mb, 3V, 75ns
  • Flash - Micron Technology - NAND02GW3B2DZA6, NAND, SLC, 2Gb, 3.3V

Front End

  • RF LNA / Splitter - Broadcom - BCM3445KMLGP11

I/O & Interface

  • IC Card Interface Controller - NXP Semiconductors - TDA8024TT

Power Supply

  • LNB Supply & Control IC - Allegro Microsystems - A8286SETTR-T

Humax PR-HD3000 Set Top Box - Box ContentsHumax PR-HD3000 Set Top Box - Box Contents

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