reverse costing analysis

© 2011 by SYSTEM PLUS CONSULTING, all rights reserved. Enphase M215 Microinverter

July 2011 – Version 1written by : Wilfried THERON

DISCLAIMER : System Plus Consulting provides cost studies based on its knowledge of the manufacturing and selling prices of electronic components and systems. The given values are realistic estimates which do not bind System Plus Consulting nor the manufacturers quoted in the report. System Plus Consulting is in no case responsible for the consequences related to the use which is made of the contents of this report. The quoted trademarks are property of their owners.

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Table of Contents1. Overview / Introduction……………………….…...…3

– Introduction– Main Features– Specifications overview of the inverter– The course of the analysis

2. Physical Analysis………………………………...…...8– Views and dimensions of the inverter– Inverter Opening– Identification of the parts– Electronic Board – Top Side - Global View– Electronic Board – Top Side - High Resolution Photo– Electronic Board – Top Side - PCB Markings– Electronic Board – Top Side – Main Components Markings– Electronic Board – Top Side - Main Components– Electronic Board – Top Side - Discrete Components– Electronic Board – Top Side – Other Components– Electronic Board – Bottom Side - Global View– Electronic Board – Bottom Side - High Resolution Photo– Electronic Board – Bottom Side - PCB Markings– Electronic Board – Bottom Side – Main Components Markings– Electronic Board – Bottom Side - Main Components– Electronic Board – Bottom Side - Discrete Components– Electronic Board – Top Side – Other Components

3. BOM Cost……….…………………………………………..…..37– Assessing the BOM– Estimation of the cost of the PCB– Estimation of the cost of the ENPHASE MB87S3051– Estimation of the cost of the Electronic Board– Assessing the Housing, Mechanical Parts– Material cost breakdown

4. Added Value Cost………………... …………………………...50– Assessing the Added Value (AV) cost– Electronic Board Manufacturing Flow– Electronic Board Hourly Rates and Cadencies– Details of the Electronic Board AV Cost– Details of the System Assembly AV Cost– Details of the Final Functional Test AV Cost– Added Value cost breakdown

5. Estimation of the selling price……………………………….60– Manufacturing Cost Breakdown– Estimation of the Selling Price

6. Conclusion…………………………………...………………….67



Inverter Opening

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GroundingCable Hook

Top Cover Housing

Screw Phillips Diam. 5mm Height 18mm with washer

Screw Torx10Diam. 3mm Height 18mm (x8)

SerialAdhesiveLabel

Aluminum Disk Plug (Big)

Aluminum Disk Plug (Small)

Note : the Aluminum disk Plugs are used for the epoxy resin potting step to fill the holes.

Back Cover Housing

Note : the Back Cover Housing is completely filled with epoxy resin.



Inverter Opening

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The epoxy resin has been removed manually, meticulously, using the blade of a scalpel, to avoid damaging the components and their markings.

Image intentionally blurred



Inverter Opening

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Due to the epoxy resin potting on the other side of the Electronic Board, it was impossible to remove the Electronic Board from the Back Cover Housing without cutting the Back Cover Housing.

Due to the epoxy resin potting on the other side of the Electronic Board, it was impossible to remove the Electronic Board without cutting the Back Cover Housing.

Back Cover Housing(cut in several parts)

Bottom side of the Electronic Board which is fully covered by epoxy resin potting.



Inverter Opening

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For the bottom side, the epoxy resin has been removed manually too.




Electronic Board – Top Side – Main Components

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Fairchild Ref. xxx Fct xxx

Texas Instruments Ref. xxx Fct xxx

STMicroelectronics Ref. xxx Fct xxx)

STMicroelectronics Ref. xxx Fct xxx

Silicon Labs Ref. xxx Fct xxxEnphase

Ref. xxx Fct xxx

Epcos Ref. xxx Fct xxx





Image intentionally

blurred



Estimation of the cost of the ENPHASE MB87S3051

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The cost of the ENPHASE MB87S3051 has been estimated with our IC Price+ software.

The cost of an Integrated Circuit varies according to the used technology as well as the size of the die and a lot of parameters such as number of metallization, manufacturing yields, test durations, functional blocks, …

ENPHASE MB87S3051


http://www.systemplus.fr/index.php?lang=us&page=icprice.php

© 2011 by SYSTEM PLUS CONSULTING, all rights reserved. Enphase M215 Microinverter 9

Die dimensions : x.xxmm x x.xxmm = xx.xxmm².Main blocks: xxxTechnology: xxxWafer fab unit: xxx

Markings on the die


ENPHASE MB87S3051





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Results calculated by IC Price+ Software for the circuit:

• We have estimated that in 2011, the manufacturing cost of the component will be $x.x.

•The selling price is estimated to $x.x for 1 million units in 2011.



Electronic Board – Bill of Material

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ICs16% Discretes

4%

Passives22%

PCB12%

Display1%

Power Module12%

Interconnect15%

Packaging1%

Housing17%

Material Cost Breakdown

Material cost breakdown

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The Electronic and Electrical components represent xx% of the total material cost of $xxx.

Designation Costs ($) (%)ICs xx xx

Discretes xx xxPassives xx xx

PCB xx xxInterconnect xx xx

Housing xx xxTOTAL xx xx



In circuit test (possible rework)

From the Screen Printing step to the Optical Test : these manufacturing steps are carried out in serial (the slowest equipment causes an additional immobilization of the other equipment).

The Functional Test and Conditioning are carried out independently.

Electronic Board Manufacturing Flow

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Manual Placement of Through Hole Components

Wave Soldering

Same operations for the 2d side



Details of the Electronic Board AV Cost

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reverse costing analysis

Documents

system plus consulting

fct xxxepcos

fct xxxstmicroelectronics

fct xxxenphase

fct xxximage

enphase mb87s30518the

epoxy resin potting

cover housing note