Set-top Box

BT Vision+ (Gen2) DVR Set Top Box Teardown

29 June 2010
The following is an overview of a teardown analysis conducted by IHS Benchmarking.

Overview / Main Features

The BT Vision+ DVR Set Top Box under analysis here is the second generation Vision+ box manufactured for the UK-based telecom provider. The HD capable DVR comes with a 160GB hard disk drive and internet connectivity. Audio/Video outputs include SPDIF, S-Video, SCART and HDMI.

BT Vision+ (Gen2) DVR Set Top Box Main ImageBT Vision+ (Gen2) DVR Set Top Box Main Image

Target Market

BT subscribers


Late 2009/ Early 2010

BT Vision+ (Gen2) DVR Set Top Box - Main PCB TopBT Vision+ (Gen2) DVR Set Top Box - Main PCB Top

Pricing and Availability

Pricing - Typically, service provider branded set top box do not carry a retail price as the hardware usually is leased to the client along with service subscription.

Availability - UK

Volume Estimations

For the purposes of this teardown analysis, we have assumed a lifetime production volume of 650K 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.

BT Vision+ (Gen2) DVR Set Top Box - Main PCB BottomBT Vision+ (Gen2) DVR Set Top Box - Main PCB Bottom

Cost Notes

Main Cost Drivers Representing ~75% of total materials cost

Seagate - ST3160310CS - Hard Drive - 160GB, 3.5', SATA, 5900RPM, 8MB Buffer

Broadcom - BCM7405DQKFEBB01G - HD Digital Video/Audio Solution - SoC, 400MHz Dual Core CMT MIPS32/16e Architecture, HD/SD H.264/AVC, MPEG-2/4/VC-1/AVS, For Satellite, IP and Cable BVR STBs

Lite-On - PA-2300-1PA-ROHS - Power Supply Value Line Item - 34W (Estimated), Input 230VAC, 50Hz

Jiangmen Glory Faith PCB Co. - 4-Layer - FR4, Lead Free

Remote Control Unit

NXP Semiconductors - TDA18211HD/C2 - Tuner IC - DVB-T, w/ Integrated IF Filters & AGC Amplifier, I2C Interface (Qty:2)

Elpida - EDE5116AJBG-8E-E - SDRAM - DDR2-800, 512Mb (8M x 16bit x 4 Banks ), 1.8V (Qty:2)

Elpida - EDE5116AJBG-8E-E - SDRAM - DDR2-800, 512Mb (8M x 16bit x 4 Banks ), 1.8V (Qty:2)

NXP Semiconductors - TDA10048HN - DVB-T / H Channel Demodulator (Qty:2)

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

Direct Materials + Manufacturing $109.62

BT Vision+ (Gen2) DVR Set Top Box Cost AnalysisBT Vision+ (Gen2) DVR Set Top Box Cost Analysis

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

OEM/ODM/EMS Relationships / Manufacturing

It is our understanding that the BT Vision+ Gen2 DVR was manufactured by Pace - more specifically, the formerly Philips set top box division which Pace acquired.

Country of Origin / Volume Assumptions

Based on markings, the unit was assembled in the EU. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were also sourced in the EU.

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 hard disk drive), 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 BT Vision Gen 2 has an overall component count of 950 (excluding box contents), of which, 95 are mechanical in nature. This complexity level represents a significant reduction to prior DVR designs we've seen that are typically in the range of 1700 to 1900 parts.

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 EU nations.

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 BT Vision+ Gen 2 DVR design:

Main PCB

Audio / Video Processing

  • Set Top Box Decoder - ST Microelectronics - STi7109KWD

I/O & Interface

  • Cable Modem IC - Conexant - CX24943-17Z
  • Ethernet Switch - Infineon - PSB6970HL
  • Audio/Video Switch - ST Microelectronics - STV6417AG
  • Microcontroller - Atmel - AT89S52-24AU


  • SDRAM - Qimonda - HYB25DC512160CE-5 (Qty. 2)
  • SDRAM - Samsung Semiconductor - K4S641632K-UC60
  • Flash - Spansion - S29GL032N90FFIS3
  • Flash - Samsung Semiconductor - KFG1216U2B-DIB6

Front End

  • QAM Demodulator IC - ST Microelectronics - STV0297E
  • Broadband Tuner - Microtune - MT2060F

BT Vision+ (Gen2) DVR Set Top Box - Box ContentsBT Vision+ (Gen2) DVR Set Top Box - Box Contents

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