Hello All,

This post dedicated to Joker TV manufacturing process. Technical and financial aspects will be covered. For Joker TV hardware description please check this post.

Spoiler: cost of one “Joker TV stand-alone” can be as low as $58.52 (if we order 1000 pcs.). For more information please check calculations below.

Cost of manufacturing

I have asked several Chinese factories to prepare quotation for first Joker TV batch. Say, 100 pcs and 1000 pcs. Following factories sent quotations:

Factory nameLocationWeb site
FASTPCBAShenzhen, Chinahttp://www.pcbapcb.com/
Creat Electronic Group Co., Ltd.Shenzhen, Chinahttp://www.creat-pcba.com/
Moko Technology Ltd.Shenzhen, Chinahttp://www.mokotechnology.com/
Wonderful Technology Co.,Ltd.Shenzhen, Chinahttp://www.wonderfulpcb.com/

Here is the table with received quotations (all costs in USD):

FactoryQty (pcs)BOM cost (per 1 pcs), USDPCB (per 1 pcs), USDAssembly cost (per 1 pcs), USDSetup cost for first order, USDTotal cost, USDCost per 1 pcs. of final product, USDLead time
FASTPCBA10073.176.76.21210981798.174 weeks
FASTPCBA100065.013.945.7515607626076.264 weeks
Creat Electronic Group Co., Ltd.10076.242.145.46350873487.344 weeks
Creat Electronic Group Co., Ltd.100057.231.954.373006385063.854 weeks
Moko Technology Ltd. 10054.325.727.550675967.594 weeks
Moko Technology Ltd. 100054.322.41.805852058.524 weeks
Wonderful Technology Co.10067.62.7510.6450854585.454 weeks
Wonderful Technology Co.100055.692.757.806624066.244 weeks

Final product

Here is a photo of final product. For stand-alone version extruded aluminum enclosure used.

 

How “Joker TV stand-alone” actually looks like

BOM cost (per 1 pcs), USD

A bill of materials (BOM) is the raw cost of electronics components required to assembly 1 pcs of Joker TV module. Totally 87 items used. This table contain BOM quotation (Creat Electronic Group Co. quote used as example):

ItemRefDesQty.Part NameDescriptionMfg. P/NPrice of 100pcs Price of 1000pcs Up Side QtyDown Side QtyManufacturer
1L[23-24]20603CS-R15XJLWINDUCTOR SMD 0603 (1608 Metric)150nH ?% 280mA0.9231.8460.0620.12320Coilcraft Inc
2L3610603CS-R22XGLWINDUCTOR SMD 0603 (1608 Metric)220nH ?% 200mA1.0001.0000.0620.06210Coilcraft Inc
3L22,L35,L37,L3940603CS-R27XGLWINDUCTOR SMD 0603 (1608 Metric)270nH ?% 170mA1.1544.6150.0620.24640Coilcraft Inc
4L[1-2],L[4-5],L[7-8],L[10-16],L[18-21],L4118BLM18EG221SN1DFerrite chip EMIFIL BLM18x 0603 (1608)220 Ohm 2A0.1232.2150.0380.692180Murata
5L25,L28,L31,L344BLM18EG601SN1DFerrite chip EMIFIL BLM18x 0603 (1608)600 Ohm 0.5A0.1540.6150.0380.15440Murata
6L3,L6,L173CDRH74NP-100MCPOWER INDUCTOR 10UH 1.84A 7.5x7.5mm SMD10uH 1.84A0.3851.1540.1540.46230SUMIDA AMERICA COMPONENTS INC
7L301CDRH74NP-220MCPOWER INDUCTOR 22UH 1.23A 7.5x7.5mm SMD22uH 1.23A0.3850.3850.1540.15410SUMIDA AMERICA COMPONENTS INC
8L91CDRH74NP-330MCPOWER INDUCTOR 33uH 0.96A 7.5x7.5mm SMD33uH 0.96A0.3850.3850.1540.15410SUMIDA
9L381CLH1005T-12NJ-SINDUCTOR (Chip Coil) 040212nH?% 300mA0.0310.0310.0080.00810Yageo
10L26,L322CLH1005T-22NJ-SINDUCTOR (Chip Coil) 040222nH?% 300mA0.0310.0620.0080.01520Yageo
11L29,L332CLH1005T-3N3S-SINDUCTOR (Chip Coil) 04023,3nH 400mA +-0,3nH 0.0310.0620.0080.01520Yageo
12L271CLH1005T-5N6S-SINDUCTOR (Chip Coil) 04025.6nH 400mA +-0,3nH 0.0310.0310.0080.00810Yageo
13L401LQW2BHN27NJ03LINDUCTOR (Chip Coil) 080527nH?% 540mA0.4620.4620.2770.27710Murata
14C173,C1972GRM1555C1H101JZ01DCAP CERAMIC 0402 (1005 metric)100pF 50V C0G 5%0.0080.0150.0030.00620Murata
15C9,C15,C22,C24,C42,C44,C53,C58,C132,C151,C153,C163,C[168-169],C184,C19616GRM1555C1H102JA01DCAP CERAMIC 0402 (1005 metric)1000pF 50V C0G 5%0.0080.1230.0030.049160Murata
16C1831GRM1555C1H121JA01DCAP CERAMIC 0402 (1005 metric)120pF 50V C0G 5%0.0080.0080.0030.00310Murata
17C1621GRM1555C1H151JA01DCAP CERAMIC 0402 (1005 metric)150pF 50V C0G 5%0.0080.0080.0030.00310Murata
18C1921GRM1555C1H1R8CA01DCAP CERAMIC 0402 (1005 metric)1.8pF 0.25pF 50V C0G0.0080.0080.0030.00310Murata
19C[179-180]2GRM1555C1H220JZ01DCAP CERAMIC 0402 (1005 metric)22pF 50V C0G 5%0.0080.0150.0030.00620Murata
20C1911GRM1555C1H3R9CA01DCAP CERAMIC 0402 (1005 metric)3.9pF 0.25pF 50V C0G0.0080.0080.0030.00310Murata
21C1821GRM1555C1H470JZ01DCAP CERAMIC 0402 (1005 metric)47pF 50V C0G 5%0.0080.0080.0030.00310Murata
22C1591GRM1555C1H471JA01DCAP CERAMIC 0402 (1005 metric)470pF 50V C0G 5%0.0080.0080.0030.00310Murata
23C1951GRM1555C1H680JA01DCAP CERAMIC 0402 (1005 metric)68pF 50V C0G 5%0.0080.0080.0030.00310Murata
24C1901GRM1555C1H6R8DZ01DCAP CERAMIC 0402 (1005 metric)6.8pF 50V C0G 0.5pf0.0080.0080.0030.00310Murata
25C1781GRM1555C1HR50CZ01DCAP CERAMIC 0402 (1005 metric)0.5pF 0.25pF 50V C0G0.0080.0080.0030.00310Murata
26C110,C[133-134],C[137-140],C[142-143],C161,C[166-167],C[170-171],C17415GRM155R60J105KE19DCAP CERAMIC 0402 (1005 metric)Cap Ceramic 1uF 6.3V X5R 10%0.0080.1150.0030.046150Murata
27C[1-2],C[6-8],C10,C12,C14,C[16-21],C23,C[26-29],C31,C[34-37],C41,C45,C[47-52],C[54-55],C57,C[59-65],C[69-70],C[73-74],C77,C[79-80],C[89-92],C94,C[96-97],C[99-101],C[103-107],C[113-118],C[122-125],C129,C136,C141,C146,C[149-150],C154,C158,C160,C164,C172,C177,C181,C18588GRM155R71C104KA88DCAP CERAMIC 0402 (1005 metric)0.1uF 16V X7R 10%0.0080.6770.0030.271880Murata
28C1551GRM155R71C224KA12DCAP CERAMIC 0402 (1005 metric)0.22uF 16V X7R 10%0.0080.0080.0030.00310Murata
29C11,C13,C25,C30,C32,C43,C56,C84,C87,C108,C[111-112],C119,C128,C14815GRM155R71E103KA01DCAP CERAMIC 0402 (1005 metric)0.01uF 25V X7R 10%0.0080.1150.0030.046150Murata
30C5,C46,C147,C1524GRM155R71H472KA01DCAP CERAMIC 0402 (1005 metric)4700pF 50V X7R 10%0.0080.0310.0030.01240Murata
31C157,C165,C175,C186,C1935GRM188R71C105KA12DCAP CERAMIC 06031uF 16V X7R 10%0.0080.0380.0030.01550Murata
32C4,C402GRM21BR61C106KE15LCAP CERAMIC 080510uF 10% 16V X5R0.0150.0310.0110.02220Murata
33C[38-39],C[67-68],C72,C[81-83],C88,C98,C[144-145]12CL10A226MQ8NRNCCAP CERAMIC 060322uF 20% 6.3V X5R0.0150.1850.0120.148120Samsung
34C33,C66,C75,C1354CL10A475KO8NNNCCAP CERAMIC 06034.7uF 10% 16V X5R0.0150.0620.0080.03140Samsung
35C71,C1942GRM21BR71H224KA01LCAP CERAMIC 08050.22uF 10% 50V X7R0.0150.0310.0080.01520Murata
36C156,C176,C[187-188]4CL32B226KAJNFNECAP CERAMIC 1210 (3225 metric)22uF ?0% 25V X7R0.3851.5380.0770.30840Samsung
37C31TAJA106K010RNJCAPACITOR TANT SMD Size A (3216-18)10uF 10V 3 Ohm0.3850.3850.1540.15410AVX Corporation
38C189,C1982TCJD107M010R0080CAP TANT Low ESR SMD Size D (7343)100uF ?0% 10V 80 mOhm1.5383.0771.1542.30820AVX Corporation
39RA[1-4]4CAY10-470J4LFRESISTOR ARRAY 4x0402 CONVEX 080447 ?%0.0150.0620.0080.03140Bourns
40R[21-22],R24,R[26-28],R747RC0402JR-07100RLRC0402 1/16W 5% SMDR0402, 5%, 1000.0080.0540.0030.02270Yageo
41R34,R49,R[53-54],R665RC0402JR-07100KLRC0402 1/16W 5% SMDR0402, 5%, 100K0.0080.0380.0030.01550Yageo
42R[4-6],R9,R[15-20],R43,R[50-52],R[55-56],R75,R7718RC0402JR-0710KLRC0402 1/16W 5% SMDR0402, 5%, 10K0.0080.1380.0030.055180Yageo
43R761RC0402 1/16W 5% SMDR0402, 5%, 130K0.0080.0080.0030.00310Yageo
44R78,R802RC0402JR-071KLRC0402 1/16W 5% SMDR0402, 5%, 1K0.0080.0150.0030.00620Yageo
45R811RC0402JR-071MLRC0402 1/16W 5% SMDR0402, 5%, 1M0.0080.0080.0030.00310Yageo
46R[1-2],R[69-70],R[82-83]6RC0402JR-07270RLRC0402 1/16W 5% SMDR0402, 5%, 2700.0080.0460.0030.01860Yageo
47R111RC0402JR-074R7LRC0402 1/16W 5% SMDR0402, 5%, 4.70.0080.0080.0030.00310Yageo
48R23,R25,R33,R40,R63,R676RC0402JR-074K7LRC0402 1/16W 5% SMDR0402, 5%, 4.7K0.0080.0460.0030.01860Yageo
49R791RC0402JR-074M7LRC0402 1/16W 5% SMDR0402, 5%, 4.7M0.0080.0080.0030.00310Yageo
50R3,R14,R[29-32],R[35-39],R[44-46],R65,R7116RC0402JR-0747RLRC0402 1/16W 5% SMDR0402, 5%, 470.0080.1230.0030.049160Yageo
51R[47-48],R[57-62]8RC0402JR-070RLRC0402 1/16W Jumper SMDR0402, 00.0080.0620.0030.02580Yageo
52R421RC0603FR-0710K5LRC0603 1/10W 1% SMDR0603, 1%, 10.5K0.0080.0080.0030.00310Yageo
53R7,R12,R723RC0603FR-0710KLRC0603 1/10W 1% SMDR0603, 1%, 10K0.0080.0230.0030.00930Yageo
54R41,R852RC0603FR-072KLRC0603 1/10W 1% SMDR0603, 1%, 2K0.0080.0150.0030.00620Yageo
55R731RC0603FR-073K83LRC0603 1/10W 1% SMDR0603, 1%, 3.83K0.0080.0080.0030.00310Yageo
56R131RC0603FR-0731K6LRC0603 1/10W 1% SMDR0603, 1%, 31.6K0.0080.0080.0030.00310Yageo
57R81RC0603FR-075K11LRC0603 1/10W 1% SMDR0603, 1%, 5.11K0.0080.0080.0030.00310Yageo
58R841RC0603FR-078K06LRC0603 1/10W 1% SMDR0603, 1%, 8.06K0.0080.0080.0030.00310Yageo
59VD[2-4],VD[6-7],VD[9-11]8NUP1301ML3T1GESD DIODE 70VWM SOT-230.0920.7380.0460.36980ON Semiconductor
60VD11PMEG2020EJSCHOTTKY RECT 20V 2A SOD323F0.2310.2310.1770.17710Philips
61VD5,VD82PMEG4010BEADIODE SCHOTTKY SOD323 (SC-76)40V 1A0.1380.2770.1230.24620NXP Semiconductors
62VD121LNBTVS3-220UTVS UNIDIRECT 1500W 3KV SMB22V0.4000.4000.3230.32310STM
63DD21EP4CE22F17C8NIC CYCLONE IV FPGA 22K 256-FBGA12.69212.69212.30812.30810Altera
64DD11M25P128-VME6GBIC FLASH 2.7-3.6V 8VDFPN128Mbit1.1541.1540.9620.96210Micron
65DA11NCP1117ST25T3GIC REG 800MA LDO SOT-2232.5V0.1920.1920.1920.19210ON Semiconductor
66DD61SN74LVC1G125DBVRIC BUS BUFF TRI-ST N-INV SOT23-50.0620.0620.0540.05410Texas Instruments
67DD81SN74LVC2G04DBVRIC DUAL INVERTER GATE SOT-23-60.0920.0920.0920.09210Texas Instruments
68DD[3-5]3SN74LVCH245APWRIC BUS TRANSCEIVER DUAL 20TSSOP0.2080.6230.2080.62330Texas Instruments
69DA[2-3],DA5,DA94ST1S10PURIC REG STEPDOWN 3A 900KHZ DFN80.4851.9380.4851.93840STMicroelectronics
70DD71TCA9517DRIC I2C BUS Level-Shifting REPEATER 8-SOIC0.6920.6920.6920.69210Texas Instruments
71DA4,DA122TPS2041BDRIC PWR DIST SWITCH SNGL 8-SOIC0.2000.4000.1770.35420Texas Instruments
72DA101TPS65233RTERIC LNB CTRL STEP-UP I2C 16-VFQFPN0.4620.4620.4310.43110Texas Instruments
73DD91USB3340-EZK-TRIC USB 2.0 TXRX 32QFN1.1541.1541.0771.07710Microchip
74GQ11ASE-27.000MHZ-LC-TOSCILLATOR 3.3V SMD 3.2x2.5mm27.000MHz ?0ppm1.6921.6920.5000.50010Abracon
75ZQ21ABM3B-26.000MHZ-10-1-U-TCRYSTAL 26MHZ 10PF SMD26.0MHz0.9230.9230.1920.19210Abracon Corp.
76ZQ11CS325S-24.000ABJTCRYSTAL 20.5MHZ 18PF SMD24.0MHz1.0461.0460.1540.15410Citizen Finetech Miyota
77HL[1-2]2LTST-C195KGJRKTLED GRN/RED BICLR 0606 SMD0.0460.0920.0230.04620Lite-On Inc
78VT11IRLML0040TRPBFMOSFET N-CH 40V 3.6A SOT-23-30.1540.1540.1540.15410International Rectifier
79MECH[1-2]27511A85LIGHT PIPE RIGHT ANGLE0.8461.6920.5541.10820CHICAGO MINIATURE LIGHTING, LLC
80XS111981568-1CONN USB AB MICRO0.1540.1540.1380.13810TE Connectivity
81XW[1-2]2VF312CONN F JACK STR 75 OHM EDGE MNT0.6151.2310.4620.92320Cinch Connectivity Solutions Vitelec
82XP21PLD-10CONN HEADER VERT 10POS 2.54 30AU0.0770.0770.0540.05401
83XP11A01A5B0030Y0P47CONN HEADER PCMCIA 5V SMT0.0000.0000.0000.00001Concraft
84DA71ATBM8881IC Demodulator DTMB/DVB-C QFN-480.0000.0000.0000.00010AltoBeam
85DA81CXD2854ERIC Combined Demodulator0.0000.0000.0000.00010SONY
86DA111CXD2858ERIC Tuner DVB-T/T2/C/C2/S/S2 ISDB-T/S0.0000.0000.0000.00010Sony
87DA61LG3306AIC Demodulator ATSC A/53 8VSB, ITU-T J.83B 64/256QAM QFN-480.0000.0000.0000.00010LG

PCB (per 1 pcs), USD

The cost of bare printed circuit board (PCB). More info about PCB can be found on Wikipedia.

Actual Joker TV PCB layers stack-up

 

Assembly cost (per 1 pcs), USD

Cost charged by factory for assembling one board. This process contains SMT elements placing, soldering, etc. For more information you can check this interesting video about PCB assembling

 

Setup cost for first order, USD

One time cost for manufacturing special tools and materials for Joker TV. For example, PCB stencil. The purpose of an PCB stencil is to transfer solder paste to a PCB.

Total cost, USD

Depending on “Qty (pcs)” row this cost is total cost for 100 or 1000 pcs. of Joker TV modules.

Cost per 1 pcs.

This cost is calculated by “Total cost, USD”/”Qty” and represents final cost of 1 pcs. of Joker TV module. We will use this cost for later calculations.

Print Friendly

Leave a Reply

Your email address will not be published. Required fields are marked *