Xiaomi Smart LED TV 43” Teardown, BOM and Should 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.

Smart LED TV Teardown, Bill of Materials & Should Costing and Analysis

Prominent Features of Smart LED TV

A comprehensive teardown and benchmarking of the Smart LED TV 43” was conducted, analyzing 43 features, specifications, and product-level details. Highlighted below are some of the standout features:

Smart LED TV Display Technology

The Smart LED TV 43” has a 4K UHD display with a resolution of 3,840 × 2,160 pixels. The screen supports a wide color gamut, covering 94% of the DCI-P3 spectrum, and displays 1.07 billion colors. With a refresh rate of 60Hz and MEMC technology up to UHD 60Hz, it ensures smooth visuals. The viewing angle stands at 178° horizontally and vertically, providing consistent picture quality from various positions. Additionally, the TV supports HDR10 and HLG for enhanced dynamic range.

Resolution:

4K UHD display with 3,840 × 2,160 resolution.

Color Gamut:

Wide color gamut covering 94% of DCI-P3 spectrum

Color Depth:

1.07 billion colors for vivid visuals.

Refresh Rate:

60Hz refresh rate with MEMC technology

Audio Performance of Smart LED TV

Equipped with two 15W speakers, the TV delivers a total sound output of 30W. It supports Dolby Audio™, DTS:X, and DTS® Virtual:X sound technologies, offering an immersive audio experience with clear dialogue and rich bass.

Sound Output:

30W total sound output (2 x 15W speakers).

Audio Technology:

Dolby Audio™, DTS:X, and DTS® Virtual:X support

Sound Quality:

Clear dialogue and rich bass.

Features of Smart LED TV

Operating System:

Google TV™ with access to apps like Netflix, Prime Video, and YouTube.

Voice Control:

Built-in Google Assistant for voice control.

Streaming Support:

Chromecast and Miracast support for easy streaming

App Store:

Google Play Store for downloading apps like Netflix, Prime Video, and YouTube

Processing and Storage Features of Smart LED TV

Processor:

Quad A55 CPU and Mali G52 MP2 GPU for smooth performance

Memory and Storage:

2GB RAM and 8GB internal storage and Mali G52 MP2 GPU for smooth performance

Bill of Materials (BOM) of Smart LED TV 43”

We conducted a detailed teardown of the Smart LED TV 43” 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.

Smart LED TV Weight Distribution Analysis.

Smart TV Weight Distribution Overview:

The teardown of the Smart LED TV 43” provided insights into the weight distribution across various assemblies, highlighting the contribution of key components.

The television unit itself accounts for 70.66% of the total weight, comprising key functional elements such as the display panel, PCBs, and power supply. The packaging weight (27.66%) reflects the necessity of secure transit protection, while accessories and the remote contribute minimally to the overall weight.

Major Components Weight Contribution of Smart LED TV

Panel Rear: 2280g – Forms a significant portion of the structural weight, providing support and protection.
Packaging (Outer Box): 1944g – Essential for transportation safety.
Crystal Black Panel: 743g – Major component in the display assembly.
Crystal Black Panel Inside Layer: 742g – Works alongside the outer panel to enhance display performance.

Manufacturing Category Distribution Analysis of Smart LED TV

A detailed teardown and benchmarking study of the Smart LED TV 43” identified various manufacturing categories based on component types and production processes. This analysis helps in understanding the sourcing and fabrication techniques used in its construction.

Overview of the Manufacturing Category Distribution of Smart LED TV

This category-wise distribution provides insights into the various materials and components used in the manufacturing of the Xiaomi Smart TV 43”. The Mechanical Bought-Out Parts (BOP) (39.04%) form the largest segment, followed by bolts (19.25%) and hard consumables (8.56%). PCBs account for 5.35%, reflecting the electronic complexity of the device.

The combination of moulding, fabrication, and packaging elements highlights the diverse manufacturing techniques used in assembling the television. This structured approach ensures durability, efficient production, and seamless integration of components.

Smart LED TV Multi-level BOM (Bill of Materials) Structure

After the teardown, we used a Multi-level BOM (Bill of Materials) structure, which provides detailed insights into the main assemblies, their sub-assemblies, and individual components. This approach ensures a comprehensive analysis of the product's design, material composition, and functionality.

The BOM (Bill of Materials) structure for the Smart LED TV, with the number of assemblies and their child components, is summarized in the table below:

Above image is of xcPEP BOM (Bill of Material) page view

Smart TV Teardown and Detailed BOM (Bill of Materials) Analysis

Total Assemblies and Components - After teardown, 4 assemblies and 112 components were identified in the Xiaomi Smart TV.
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.

The BOM (Bill of Materials) structure for the Xiaomi Smart TV, with the number of assemblies and their child components, is summarized in the table below:

PCB Details of Smart LED TV

The Xiaomi Smart TV 43” is powered by an interconnected network of 9 printed circuit boards (PCBs), each designed for specific functionalities. These PCBs are meticulously engineered to provide efficient processing, signal transmission, power management, and user interface control. The cost structure of these PCBs is influenced by critical components that contribute to their functionality and overall manufacturing expenses.

High-Value Components in PCB BOM

T-CON PCB in Smart LED TV:

The Timing Controller PCB (T-CON) manages the display’s refresh rate and color accuracy while ensuring stable signal transmission between the motherboard and the display panel through its connector. It contains various resistors, capacitors, and an IC crucial for display performance.
Component Breakdown:
- Capacitor: 34
- Resistor: 69
- IC: 1
- Total Components: 119
- Copper Layers: 4

Motherboard PCB in Smart LED TV:

The motherboard is the primary processing hub, responsible for video rendering, connectivity, and overall system operations. It integrates essential components like an antenna connector, Wi-Fi & Bluetooth module, and multiple ICs for optimized performance.
Component Breakdown:
- Capacitor: 160
- Resistor: 265
- IC: 9
- Total Components: 500
- Copper Layers: 2

It integrates multiple critical components that significantly impact performance and system reliability:

Antenna Connector: Supports wireless signal reception and transmission.
IC: A processing unit essential for core system functions.
Transistor: Plays a role in power regulation and circuit stability.
Wi-Fi & Bluetooth Module: Enables seamless wireless communication.
Capacitor & Film Capacitor: Used for voltage regulation and noise filtering.
Connector FFC (20 Position & 60 Position): Ensures flexible and high-speed data transmission.
Jack Modular Connector 6P6C: Facilitates network and communication interfaces., used for network and communication interfaces.

Panel PCB 1 in Smart LED TV:

Handles signal processing and synchronization to optimize image clarity and response time. It consists of multiple resistors, capacitors, and ICs that ensure efficient display communication.
Component Breakdown:
- Capacitor: 28
- Resistor: 21
- IC: 1
- Total Components: 58
- Copper Layers: 4

Panel PCB 2 in Smart LED TV:

Facilitates efficient data transmission between the mainboard and the display panel, ensuring smooth visual output. It includes essential passive components and connectors for maintaining signal integrity.
Component Breakdown:
- Capacitor: 22
- Resistor: 29
- IC: 1
- Total Components: 52
- Copper Layers: 4

Power Switch PCB in Smart LED TV:

Regulates power flow and ensures protection through controlled voltage distribution. It is designed with essential capacitors and resistors for power stabilization.
Component Breakdown:
- Capacitor: 2
- Resistor: 4
- Total Components: 11
Copper Layers: 2 Controls power distribution and safety mechanisms.

LED Strip PCBs (3 units) in Smart LED TV:

Integrated within the display panel to provide uniform backlighting and enhance brightness consistency. Each LED strip contains multiple LEDs and connectors for stable power distribution.
Component Breakdown:
- LED: 24
- Connector: 3
- Total Components: 27
- Copper Layers: 1 Provide backlighting for the display panel.

Remote PCB in Smart LED TV Remote:

Enables Bluetooth communication for seamless remote-control functionality, integrating essential circuitry for command transmission. The PCB is compact, designed to house all necessary components for signal processing.
Component Breakdown:
- Capacitor: 16
- Resistor: 8
- IC: 1
- Total Components: 25
- Copper Layers: 1

Should Costing Analysis of Smart LED TV 43”

Detailed Should Costing Breakdown of Smart LED TV

The Smart LED TV 43” was analyzed to estimate its manufacturing cost using a detailed should costing approach. The study considered factors such as material costs, labor, production volumes, and component sourcing. Below are the key insights from the study:

The television was manufactured in India.
The estimated production volume for the study was set at 50,000 units annually.
The latest material rates and labor cost benchmarks were taken for Q3 FY24-25.

The above image shows the Should-Cost of the Panel Rear in xcPEP software.

The breakdown below provides insights into the major cost drivers in accessories, packaging, remote, and the tv.

Cost Contribution Analysis of Smart LED TV Accessories

The total cost of accessories amounts to ₹21.47, contributing to essential components used in the television setup.

Cost Contribution in Packaging

The total cost of packaging stands at ₹260.49, ensuring the safety and secure transportation of the television.

Cost Contribution in Remote

The total cost of the remote amounts to ₹315.07, driven largely by electronic components.

Cost Contribution in Television Assembly

The television assembly constitutes the most significant portion of the total cost, amounting to ₹7,695.82. Below is the breakdown of the major cost contributors:

PCB's Cost Contribution Analysis of Smart LED TV

The total cost of all PCBs used in the Xiaomi Smart TV 43” amounts to ₹5,111.13. Below is the cost distribution among the different PCBs:

To assess the impact of PCB costs relative to the total cost of the Xiaomi Smart TV 43”, we compare the total PCB cost (₹5,111.13) with the complete should cost of the television, including all assemblies (₹8,292.85):

Key Insights:

PCBs contribute 61.65% of the total cost, highlighting their role as the most expensive subsystem
Television assembly accounts for 92.80% of the total cost, indicating that internal electronics and display components dominate the pricing.
Packaging, remote, and accessories together contribute 7.2%, showing a relatively smaller cost impact.

Final Should-Cost Summary and Key Observations for Smart LED TV

We recently estimated the should-cost for the Xiaomi Smart TV 43” at ₹22,655.46 (excluding GST). This estimation is based on a detailed breakdown of component costs across different assemblies, including PCBs, television assembly, packaging, accessories, and remote.

Smart LED TV Should-Cost Analysis: Key Takeaways

PCBs contribute ₹5,111.13 (22.57%) of the total cost, making them a significant cost driver. Optimizing PCB sourcing and design could yield substantial cost savings.
The Motherboard PCB alone costs ₹3,589.3 (15.85%), making it the most expensive individual component. It remains a key focus for cost reduction and supply chain efficiency.
Display and Panel Components (₹787.9, 3.48%) are critical for manufacturing but contribute a smaller share of the total cost compared to PCBs.
Packaging (₹260.49, 1.15%) and Accessories (₹21.47, 0.09%) account for minimal cost impact, with limited scope for cost-saving measures.
The remote (₹315.07, 1.39%), while a small portion of the total cost, remains necessary for product usability.

Final Takeaways from the Smart LED TV Analysis

The top three cost-driving components (Motherboard PCB, Display Panels, and Other PCBs) collectively account for over 42% of the total cost. Focusing on cost optimizations in PCB sourcing, display panel procurement, and motherboard cost reductions could significantly improve profitability while maintaining competitive pricing.