Overview / Main Features
The Samsung SMT-H3110 is one of 2 HD set top DVRs offered by Virgin Media for the "V+ cable service. The SMT-H3110 is a DVR set top with a 160GB capacity hard disk drive along with both HDMI and SCART connectivity. This custom configuration is specified by Virgin Media for their HD (720p & 1080i high definition) cable service.
As with other Virgin Media set tops, the SMT-H3110 also offers video on demand (VOD) service with internet connectivity. The set top also supports Dolby Digital 5.1 surround sound and outputs via SPDIF.
Cable Service Operators (Virgin Media)
Pricing - Reference pricing is not available since Virgin Media only leases equipment to subscribers as part in parcel of cable television service package.
Availability - Virgin Media service area (primarily UK)
For the purposes of this teardown analysis, we have assumed a lifetime production volume of 2 Million 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
Western Digital - WD1600AVJS - Hard Drive - 160GB, 3.5', SATA 3Gb/s, 7200RPM, 8Mb Buffer
ST Microelectronics - STi7109KWD - Set Top Box Decoder - HD/SD, 32-Bit 266MHz ST40 RISC CPU, for H.264 & Microsoft WMA9
HannStar - 4-Layer - FR4, Lead-Free
Shanghai Samsung Vacuum Devices - Alphanumeric Display LED - Vacuum Fluorescent Display, w/ Plastic Mounting
Power Supply Value Line Item - Input: 200-240VAC, 1.0A, Output: 5VSB/0.4A, 3.3V/1.5A, 3.9V/2.5A, 5V/4.0A, 12V/1A, 50W
Conexant - CX24943-17Z - Cable Modem IC - SoC, DOCSIS 1.1, 225MHz System Processor, Integrated IEEE802.3 MAC, MII, USB1.1 Transceiver & Host Interface
Microtune - MT2060F - Broadband Tuner - Multi-Standard, w/ Integrated IF Variable Gain Amplifier (Qty:4)
Infineon - PSB6970HL - Ethernet Switch - 7-Port, 5 10/100M Ports w/ TX/FX Interfaces, 2 TMII/MII MAC Ports
Total BOM Cost $132.20
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 assembled in Indoneisa. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were also sourced in Indoneisa.
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 Samsung SMT-H3110 DVR Set Top has an overall component count of 1912 (excluding box contents). This complexity figure is on par with other DVR set top boxes we have previously analyzed.
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 Indoneisa.
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 SMT-H3110 uses a ST Micro Set-Top Box decoder (STi7109KWD) at the core of its design. At the front end, another ST Micro part (STV0297E) handles the QAM Demodulation while a Mircotune MT2060F performs the Broadband Tuning functionalities.
There are a handful of ICs handling the I/O & Interfaces, namely, a Conexant cable modem chip, Infineon Ethernet switch, ST audio/video switch and an Atmel microcontroller.
Majority of the SDRAM memory is provided by Qimonda and likewise, majority of the Flash memory comes from Samsung.
Here is a summary of the major components used in the Samsung SMT-H3110 design:
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, DDR400, 512Mb, 2.5V
SDRAM - Qimonda - HYB25DC256160CE-5, DDR400, 256Mb, 2.5V
Flash - Spansion - S29GL032N90FFIS3, NOR, 32Mb, 90ns, 110nm MirrorBit, 3V
Flash - Samsung Semiconductor - KFG1216U2B-DIB6, OneNAND, SLC, 512Mb, 3.3V, 66MHz
SDRAM - Samsung Semiconductor - K4S641632K-UC60, 64Mb, 3.3V, 166MHz, CL=3
QAM Demodulator IC - ST Microelectronics - STV0297E
Broadband Tuner - Microtune - MT2060F
Hard Disk Drive - Western Digital - WD1600AVJS (160GB, 3.5" SATA, 7200 rpm)