Consumer Electronics Product StudiesBluetooth Earphone Teardown, BOM and Costing

Bluetooth-9-Printed Circuit Board and Electronic Child Components

Bluetooth Earphone Teardown, BOM and Costing

Disclaimer

This study was conducted entirely in-house by ASI Engineering to demonstrate the capabilities of the xcPEP® platform. The product was independently procured by ASI. No proprietary or confidential information from any other party has been used. Results are not updated after publishing.

Bluetooth Neckband Earphone: Teardown, Bill of Material & Should Costing and Analysis

Bluetooth-1-Exploded view driver
Bluetooth-2-Exploded View Earphone

Prominent Features of Bluetooth Neckband Earphone

A detailed teardown and benchmarking of the boAt Rockerz 255 Pro Bluetooth earphones were conducted, mapping key features, specifications, and information at the product level. Below are some of its prominent features:
Audio Drivers and Performance of Bluetooth Neckband Earphone
The boAt Rockerz 255 Pro is equipped with dynamic audio drivers that deliver high-quality sound. Key attributes include:
Type:

Dynamic audio drivers designed for bass-rich performance.

Driver Size:

Driver Size: 10 mm drivers providing immersive audio clarity.

Frequency Response:

Supports a wide range of frequencies for detailed sound reproduction.

Impedance:

16 ohms for enhanced compatibility with various devices.

Bluetooth-3-Fast-Charge
Bluetooth Neckband Earphone Connectivity

Detailed teardown and analysis show that the earphone is equipped with Bluetooth 5.0 technology, these earphones offer:

Faster Pairing:

Quick and reliable device connectivity.

Extended Range:

Up to 10 meters of stable connection.

Dual Device Pairing:

Simultaneous connection to two devices for convenience.

Bluetooth-4-Neckband Connectivity
Battery and Charging Technology of Bluetooth Neckband Earphone
The Mi Power Bank 3i offers dual input (Micro-USB and USB-C) and triple output (USB-A and USB-C), allowing simultaneous charging of three devices. With 18W fast charging, it delivers quick power to compatible devices, while the low-power mode ensures safe charging for delicate gadgets like fitness trackers, activated with a double-press of the power button.
Earphone
Teardown and benchmarking activity show that the Rockerz 255 Pro features a high-capacity rechargeable Lithium-Polymer battery.
Battery Life:
Up to 6 hours of playtime on a full charge.
Fast Charging:
20 minutes of charge provides 4 hours of playback.
Charging Port:
Micro-USB charging interface for universal compatibility.
Safety Features:
Overcharge and temperature protection for long-term durability.
Bluetooth-5-Charging Technology-3
Design and Comfort of Bluetooth Neckband Earphone
The teardown of boAt Rockers 255 Pro shows the earphones are designed for all-day use, focusing on comfort and durability.
Housing Material of Bluetooth Neckband Earphone:
Lightweight PP housing for ergonomic fit.
Feel and Finish of Bluetooth Neckband Earphone:
Matte exterior for a premium feel and scratch resistance.
Bluetooth Neckband Earphone Cable:
Flexible, tangle-free cable with in-line controls for ease of use.
Magnetic function of Bluetooth Neckband Earphone:
Secure fit: Magnet Keep the earbuds together when not in use, reducing tangling. Enhanced Portability: Easy to store and carry without worrying about misplacing them.
Bluetooth-7-Magnetic Functions

Teardown Analysis of Bluetooth Neckband Earphone

A meticulous teardown and benchmarking of the boAt Rockerz 255 Pro reveals the internal structure and component organization, showcasing its efficient design.
Housing and Enclosure Design of Bluetooth Earphones

The teardown and benchmarking activity shows that the boAt Rockerz 255 Pro features a durable PP plastic enclosure with a sleek matte finish for heat resistance and scratch protection.

Housing Material of Rockerz 255 Pro Earphone:

Lightweight PP plastic housing for durability and heat resistance.

Rockerz 255 Pro Earphone Accessories:

1 x USB Cable (USB A to USB C type)

2 x Large Size Earbuds

2 x Small Size Earbuds

Bluetooth-8-Earphone Accessories

Printed Circuit Board and Electronic Child Components of Bluetooth Neckband Earphone

The PCB within the earphones handles audio processing and connectivity. Key observations include:
Bluetooth Chipset:
Integrated Bluetooth 5.0 chip for seamless pairing and audio transmission.
Audio Drivers:
Precision 10mm drivers for clear sound output.
Battery:
Compact Lithium-Polymer cell with a capacity of 110 mAh.
Protection Circuits:
Safeguards against overcharge, short circuit, and overheating.
Bluetooth-9-Printed Circuit Board and Electronic Child Components

Weight of Bluetooth Neckband Earphone

Total Weight of Bluetooth Neckband Earphone
Approximately 26.69 grams for the earphone and 100 grams with packing box and accessories.
Bluetooth-10-Packaging Earphone-4
Bluetooth-11-Headphone Accessories-5
Bluetooth-12-Headphone package Items-6

Bill of Materials (BOM) Analysis of Bluetooth Neckband Earphone

The teardown and benchmarking study involved a detailed BOM analysis, mapping various assemblies and components. Below is an overview:
Summary of Assemblies and Components
We conducted a detailed teardown of the boAt Rockerz 255 Pro neckband earphone to study its components and system architecture. This teardown study involved analyzing data related to various part attributes, enabling a comprehensive understanding of its design and functionality.
Multi-level BOM (Bill of Materials) Structure of Neckband Earphone

After teardown for this analysis, we used a Multi-level BOM (Bill of Materials) structure, which provides detailed insights into the main assemblies, their sub-assemblies, and individual components.

Summary of Assemblies and Components of Neckband
The BOM (Bill of Materials) structure for the boAt Rockerz 255 Pro neckband earphone, with the number of assemblies and their child components, is summarized in the table.
Bluetooth-13-Neckband Earphone no of components Table
Bluetooth-14-Neckband Earphone no of components
Bluetooth-15-Neckband Earphone xcPEP BOM page
Above image is of xcPEP BOM (Bill of Material) page view

Neckband Earphone Teardown and Detailed BOM (Bill of Materials) Analysis

Total Assemblies and Components

After teardown, 3 assemblies and 57 components were identified in the boAt Rockerz 255 Pro neckband earphone.

Component Parameters:

Additionally, 40 BOM (Bill of Materials) parameters such as weight, dimensions, material type, electrical specifications, and thermal properties were mapped. On average, 20 parameters per part were recorded, depending on the complexity of the component.

Bluetooth Neckband Earphone Weight Distribution Analysis

Weight Distribution Overview

Total Weight and Assembly Breakdown

The total weight of the boAt Rockerz 255 Pro neckband earphone (including earphones, packaging, and accessories) is 100 grams. The weight distribution of the assemblies is as follows:

Bluetooth Headset: 26.55% (26.65grams)
Packaging: 64.33% (64.27 grams)
Accessories: 9.11% (9.15grams)

Bluetooth-16-Neckband Earphone Assembly Weight Distribution

Teardown and Weight Contribution Insights

Major Components Weight Contribution
  • Outer Box: 32.15% (32.26 grams)
  • Earphone Mount Packaging: 15% (15.06 grams)
  • Brand Flyer: 9.21% (9.25 grams)
  • Rubber Casing: 4.48% (4.5 grams)

Bluetooth Neckband Earphone Weight Pareto Analysis

Pareto Analysis of Component Weight
Bluetooth-17-Neckband Earphone Weight Pareto
Weight Pareto Insights from Teardown and Benchmarking of Earphones
  1. Outer Box
    • The Outer Box is the heaviest single component, weighing 32.26 grams, accounting for 27.3% of the total weight.
  2. Earphone Mount Packaging
    • Packaging designed to securely hold the earphones contributes 15.06 grams (12.7% of the total weight).
  3. Brand Flyer
    • The informational flyer adds 9.25 grams, making up 7.8% of the total weight.
  4. Rubber Casing - Neck Band
    • Durable and flexible, the neckband's rubber casing weighs 4.5 grams (3.8% of the total weight).
  5. Battery Cell
    • The rechargeable battery cell weighs 2.53 grams, which is 2.1% of the total weight.
  6. Earbuds Housing (Back and Front)
    • The combined weight of the back and front housings is 3.89 grams (3.3% of the total weight).

Bluetooth Neckband Earphone Manufacturing Category Distribution Analysis

Analysis of Manufacturing Categories

After detailed teardown and analysis of boAt Rockerz 255 Pro neckband earphone, we found inventory has components with different manufacturing categories and its distribution as follows:

Bluetooth-18-Neckband Earphone Manufacturing category
Overview of Manufacturing Category Distribution:
  1. Mechanical Bought-Out Part (BOP): 32.14%
    • Constitutes the majority of the components, including outsourced mechanical parts vital for operational performance.
  2. Rubber Compression Moulding (P): 14.29%
    • Covers rubberized elements such as ear tips and seals, providing comfort and durability.
  3. Paper Packaging (LA): 7.14%
    • Encompasses sustainable and protective packaging materials for the earphones.
  4. Injection Moulding (P): 7.14%
    • Used for creating precise plastic components, such as housing and casing.
  5. Aluminium Casting (P): 7.14%
    • Covers metallic components like enclosures, providing a premium aesthetic and durability.
  6. Rubber Extrusion Moulding: 7.14%
    • Accounts for cable reinforcements and flexible connectors.

Should Costing Analysis of Bluetooth Neckband Earphone

Detailed Should Costing Breakdown
We have conducted a last-level teardown on the boAt Rockerz 255 Pro Neckband Earphone and the following are some outcomes of the study. In the costing study data relating to various part-attributes are mapped. This data is analyzed for a detailed understanding of the entire boAt Rockerz 255 Pro Neckband Earphone.
Should Cost Drivers

A detailed Should Costing of boAt Rockerz 255 Pro neckband earphone was performed and the following are the outcomes of the study. The manufacturing cost of the neckband earphone was found to be 568.25 INR and the following were the consideration for the study.

  • The Neckband earphone was manufactured in Bangalore, India
  • The volumes considered for the activity were 50,000 annually
  • The latest Material rates and rates required for MHR calculations were taken for Q3 FY24-25
Bluetooth-19-Neckband Earphone Should Cost Driver table
Bluetooth-20-Neckband Earphone Should Cost Driver
Bluetooth-21-Should Costing Earphone PCB
The above image shows should cost of PCB in xcPEP software
Bluetooth Neckband Earphone Should Cost Breakdown

The total should-cost is distributed across the following assemblies:

  1. Bluetooth Headset: 90.15% of total cost (INR 512.34).
  2. Packaging: 4.56% (INR 25.93).
  3. Accessories: 5.20% (INR 29.99).
Bluetooth-22-Neckband Earphone Should Cost Breakdown
Bluetooth Neckband Earphone Should Cost Pareto Analysis
Bluetooth-23-Neckband Earphone Should Cost Pareto
Key Observations from the Earphone Should Cost Pareto

Based on the detailed breakdown of component should cost, the following observations are made:

  1. Main PCB
    • The Main PCB is the most expensive component, contributing ₹293.23, which accounts for 51.6% of the total cost. This is due to the use of Bluetooth version V5.0.
    • Its significant share in the cost highlights it as a critical focus area for cost optimization.
  2. Sound Drivers
    • The Sound Drivers are the second most expensive component, costing ₹119.66, making up 21% of the total cost.
    • Given their importance to audio performance, balancing cost and quality for this component is crucial.
  3. Battery Cell
    • The Battery Cell contributes ₹52.65, accounting for 9.2% of the total cost.
    • Its cost and performance impact make it another key area for cost reduction strategies.
Observations from the Should Costing of Earphones

Based on the detailed breakdown of component should cost, the following observations are made:

  1. Top Three Components Account for Majority Costs:
    • The Main PCB (₹293.23), Sound Drivers (₹119.66), and Battery Cell (₹52.65) together contribute 82% of the total cost, highlighting their dominance in the cost structure.
  2. Peripheral Components Have Minimal Impact:
    • Components such as the Outer Box (₹10.59), Earphone Mount Packaging (₹1.67), and Accessories Cover (₹0.42) collectively account for a small portion of the overall cost.
  3. Functional Components Drive Cost Efficiency:
    • Components like the Micro USB Connector (₹15.04) and Earbuds Housing Front and Back (₹20.78 total) represent a balance of cost and functionality, offering potential for cost optimization without compromising performance.