LG 32LE5400 LCD Television Teardown

Overview / Main Features

The LG 32LE5400 is a LED edge-lit 32-inch LCD television unit designed and sold into the North American market. The featured display panel specifications is set at 1080p resolution with 120Hz refresh rates as well as a 4,000,000:1 contrast ratio. Naturally the LG 32LE5400 features a LCD panel manufactured by LG Display. As typical of television sets designed for the North American market, the LG 320LE5400 is assembled in Mexico (nearest low cost manufacturing facility to the target market) and comes with an integrated 156W power supply. Internally, the LG is powered by a Broadcom BCM3549 video processor IC and features a LG ATSC tuner module.

LG 32LE5400 LCD Television Main Image

General Consumers

Released

Unknown

Pricing and Availability

Pricing - The LG 32LE5400 currently sells on various online retailers for approximately $900.

Availability - North America

Volume Estimations

For the purposes of this teardown analysis, we have applied a lifetime production volume of approximately 250K 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.

LG 32LE5400 LCD Television Cost Analysis

Main Cost Drivers ~80% of Total Materials Cost

LG Display - LC320EUH-SCA1 - LCD Display Panel - 32' Diagonal, 1.06B Color, 1080P, 1920x1080 Pixels, 363.75um x 363.75um Pixel Size, 4,000,000:1 Dynamic Contrast Ratio, 120Hz Refresh Rate, 2.6ms Response Time

Enclosure, Main, Front - Injection Molded Clear Polycarbonate, Painted, w/ Clear Coat

Broadcom - BCM3549 - Video Processor - Full HD 1080P DTV SoC, 400MHz Dual-Threaded MIPS Processor, Multiformat Video Decoder, 3D/2D Graphics Core, QAM & VSB Receiver, NTSC Demodulator, Ethernet MAC & PHY, & 2 DVI/HDMI Receivers

Enclosure, Main, Rear - 2 Pieces Stamped / Formed Electro-Galvanized Steel, Clinched, Painted, Printed

Accuris - 4-Layer - FR4, Lead-Free

Enclosure, Stand, Base, Outer - Injection Molded MABS, w/ Clear Coat

Enclosure, Stand Pedestal - Die-Cast Aluminum

Samsung - K4T1G084QE-HCF8 - SDRAM - DDR2, 1Gb, 128Mx8, 1.8V (Qty:4)

Loudspeaker Assembly - 1 Pair, 8 Ohm, 12W, w/ Plastic Housing, 2 2-Wire Harness, 4-Position Pin Socket Connector & Cloth Tape Insulators

Box - Corrugated Cardboard, Full Color Printed, Glossy Finished

Toshiba Semiconductor - TC58NVG2S3ETA00 - Flash - NAND, SLC, 4Gb, 3.3V, 25ns

LG Electronics - TDVJ-H031F - ATSC Tuner Module Value Line Item - Full NIM

Mstar Semiconductor - MST7378 - ASIC - TCON, & DDR3 Memory Controller

Wall Mounting Bracket - Stamped / Formed Electro-Galvanized Steel, w/ 4 Pressed-In Threaded Metal Inserts

1-Layer - CEM1, Lead-Free

Remote Control Unit

Enclosure, Stand, Base, Bottom - Stamped / Formed Electro-Galvanized Steel

Wire Harness - 24 18AWG Discrete Insulated Wires, w/ 2 24-Position Pin Socket Connectors, Ground Lug, Cloth Tape

Insulator - Polycarbonate Sheet, Die-Cut, w/ Stamped Metal Plate, & PSA

Insulator - Polycarbonate Sheet, Die-Cut, w/ Stamped Metal Plate, & PSA

Austria Micro Systems - AS3693B-ZTQ - LED Driver - 16-Channel, w/ Built-In PWM Generator

Thermal Transfer Pad - Silicone Elastomer, Die-Cut, w/ PSA (Qty:2)

Direct Materials + Manufacturing $393.12

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 Mexico. Furthermore, we have assumed that custom mechanicals (plastics, metals, etc.) were also sourced in Mexico.

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 charger unit), 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 LG 32LE5400 LCD television has an overall component count of 2538 (excluding box contents), of which 1805 components reside on the Main PCB. In comparison, Vizio E320VP the television unit has an overall complexity of 1078.

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 Mexico.

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.

LG 32LE5400 LCD Television - Box Contents