Electronics Teardown,
PCB Should Costing & VAVE
Radar sensor, EV BTMS, and wiring harness - full teardown to should cost across India, China, and European manufacturing locations
Products Analysed
3 assemblies
PCB Variants Compared
3 technologies
Bare PCB Cost
$3.05 (China)
PCBA Should Cost
$65.07 (India)
PCB Saving Found
$19.89 → $8.07
Scope of Work
What Emithran delivered
- Review existing designs of PCB, PCBA, and wiring harness to determine cost drivers using should-cost methodology
- Regional costing based on current manufacturing location (India / China / Europe)
- Complete physical teardown of assemblies and component-level identification
- PCB cross-section analysis via SEM / EDAX microscopy
- VAVE idea generation and cost reduction workshops
- Lessons learned documentation and knowledge base compilation
Execution Approach - 10-Step Should Cost
Case A - Radar Sensor Assembly Teardown
10-Component Exploded View + PCB Layer Stack Analysis
Assembly Components
LF PCB Layer Stack (6L)
RF PCB Layer Stack (4L)
Case B - Bare PCB Should Costing & Benchmarking
Main PCB · China · 65,000 units/yr · $3.046 should cost
Should Cost Breakdown - China Manufacturing
Bare PCB Technology Comparison
FR4 + PTFE
9L · 2-4b-2 HDI · OSP · 1.5mm
$12.08
€10.07
FR4 + PTFE GFLowest Cost
11L · 2-6b-2 HDI · Im.TIN · 1.65mm
$8.07
€6.73
FR4 + Ceramic GF
12L · 2-8b-2 HDI · OSP · 1.9mm
$19.89
€16.58
Case C - PCBA Should Costing · EV Battery Management System
India Manufacturing · Total: $65.074 / unit
PCBA Cycle Time Breakdown
Case D - Wire Harness Should Costing · EV Application
6-Step Methodology · Multi-Connector Harness
Annual quantity, production plant, Material Master, Assembly Drawing, GQRS
Connector specs, wire routing, shielded conductor assemblies, continuity requirements
From/to connections, terminal/seal identification, GD spec part number search
Connector, terminal & seal costs via Octopart/ciiva; preferred: TE, APTIV, MOLEX
Part No, Manufacturer, Class, Qty, Unit Cost, Currency, Source reference link
Cavity plug, terminal insertion, crimping, taping, inspection - auto-calculated cycle times
Sample Process Cost Output
| Labour Operation | Parts | Cycle Time (s) | Cost (USD) |
|---|---|---|---|
| Connector Terminal Insertion | 215 | 5s | $11.158 |
| Wire Twisting Operations | 13 | 60s | $9.461 |
| Inspection Time | 1 | 600s | $7.032 |
| Connector Electric Test | 26 | 30s | $8.270 |
| Connector Placement | 26 | 15s | $4.135 |
| Machine Terminations | 215 | 3s | $7.678 |
| Taping Operation | 1 | 180s | $2.118 |
| Total Process Cost | $81.838 | ||
Emithran Capabilities Demonstrated
End-to-end electronics cost intelligence
Cases Delivered
Radar sensor teardown, bare PCB benchmarking, PCBA should cost, and wire harness costing - all in one engagement.
SEM Microscopy Depth
Cu foil thickness, coating layers, and laminate cross-sections validated via SEM/EDAX - not estimated.
Lowest-Cost PCB Found
FR4 + PTFE GF technology (11L, Im.TIN) identified at $8.07 vs $19.89 for ceramic hybrid - $11.82 per unit saving.
PCBA Cycle Time Mapped
Testing, depaneling, manual, TH, and SMD processes individually timed and costed - full EX-Works model delivered.
For Enquiry
Need PCB teardown, should costing, or VAVE for your electronics?
Emithran's electronics team covers bare PCB, PCBA, and wire harness - from physical teardown through to supplier negotiation baseline.
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