Bluetooth Earphone Teardown, BOM & Cost Analysis

Audio Drivers and Performance

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:

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: 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 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.

Battery and Charging Technology

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.

Design and Comfort

The teardown of boAt Rockers 255 Pro shows the earphones are designed for all-day use, focusing on comfort and durability.

• Housing Material: Lightweight PP housing for ergonomic fit.
• Feel and Finish: Matte exterior for a premium feel and scratch resistance.
• Cable: Flexible, tangle-free cable with in-line controls for ease of use.
• Magnetic function: 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.

Housing and Enclosure Design

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: Lightweight PP plastic housing for durability and heat resistance.
• Accessories: 1 x USB Cable (USB A to USB C type), 2 x Large Size Earbuds, 2 x Small Size Earbuds

Printed Circuit Board and Electronic Components

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.

Weight

Approximately 26.69 grams for the earphone and 100 grams with packing box and accessories.

Bill of Materials (BOM) Analysis

The teardown and benchmarking study involved a detailed BOM analysis, mapping various assemblies and components.

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 Structure

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.

The BOM structure for the boAt Rockerz 255 Pro neckband earphone, with the number of assemblies and their child components, is summarized in the table.

Detailed BOM Analysis

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

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.

Weight Distribution Analysis

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% (26.65 grams)
• Packaging: 64.33% (64.27 grams)
• Accessories: 9.11% (9.15 grams)

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)

Weight Pareto Analysis

Weight Pareto Insights

1. Outer Box: 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%).
3. Brand Flyer: The informational flyer adds 9.25 grams, making up 7.8%.
4. Rubber Casing – Neck Band: Durable and flexible, the neckband's rubber casing weighs 4.5 grams (3.8%).
5. Battery Cell: The rechargeable battery cell weighs 2.53 grams (2.1%).
6. Earbuds Housing: Combined weight of back and front housings is 3.89 grams (3.3%).

Manufacturing Category Distribution

Overview of Manufacturing Category Distribution:

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

1. Mechanical Bought-Out Part (BOP): 32.14% – Constitutes the majority, including outsourced mechanical parts vital for operational performance.
2. Rubber Compression Moulding (P): 14.29% – Covers rubberized elements such as ear tips and seals.
3. Paper Packaging (LA): 7.14% – Encompasses sustainable and protective packaging materials.
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.
6. Rubber Extrusion Moulding: 7.14% – Accounts for cable reinforcements and flexible connectors.

Should Cost Drivers

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 cost analysis 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.

A detailed Should Cost Analysis was performed and the manufacturing cost of the neckband earphone was found to be 568.25 INR. The following were the considerations:

• 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

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).

Should Cost Pareto Analysis

Key Observations from Cost Pareto

1. Main PCB: 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 highlights it as a critical focus area for cost optimization.
2. Sound Drivers: The second most expensive component, cost analysis ₹119.66, making up 21% of the total cost. Given their importance to audio performance, balancing cost and quality is crucial.
3. 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 Should Cost Analysis

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.