EL SEGUNDO, CA -— Illustrating the trend toward increased electronics content in consumer electronics appliances, the IHS iSuppli Teardown Analysis of a General Electric washing machine has revealed a relatively high degree of semiconductor usage that allows it to reduce energy consumption.
The GE GFWN1100LWW washing machine carries a bill of materials (BOM) of $36.13 for its electronics, according to a physical dissection conducted by IHS (NYSE: IHS). Out of this total, $13.84—or 38 percent—was accounted for by semiconductors, higher than the global average.
A significant component of the higher cost was the usage of a 16-bit microcontroller (MCU) from Renesas Electronics Corp., an additional component that is used to implement intelligent motor control for power savings.
“The GFWN1100LWW washing machine employs intelligent motor control to help reduce power consumption and achieve the coveted Energy Star designation,” noted Kevin Keller, senior principal analyst, teardown analysis, for IHS. “While the use of the Renesas MCU drives up the electronics cost of the GE washing machine, it will more than pay for itself through power savings during the life of the product. Intelligent motor control through the use of MCUs is finding increased acceptance in appliances like washing machines, even in midrange models like the GFWN1100LWW. This use of chips to achieve better energy efficiency represents a growing trend in appliances that we will continue to monitor as IHS conducts more consumer appliance teardowns.”
Big energy savings from a microcontroller
The semiconductor content of the GFWN1100LWW is more than twice the $5.52 average expected for all washing machines shipping in 2012, according to IHS data. The lower cost is driven by the large quantities of low-end washing machines shipped to developing regions, such as Brazil, Russia, India and China.
The Renesas MCU represents a portion of this additional cost, at $2.89, or about 8 percent of the total electronics BOM. However, the intelligent motor control implemented through the MCU could save as much as 60 percent of the energy consumption in an appliance like the GE washing machine.
BOM breakdown
The most expensive single electronic component is the hybrid IC module containing an array of insulated gate bipolar transistor (IGBT) devices, which are power semiconductor devices used as switching for the washing machine’s motor. Supplied by International Rectifier, the IGBT driver module carries a cost of $5.25, representing about 15 percent of the BOM.
Other major components contributing to the GFWN1100LWW’s BOM include:
The printed circuit board (PCB), from Century Printed Circuits, costing $2.98
A relay, from TE Connectivity, at $2.82
An electrolytic capacitor from Chemi-Con, at $2.12
A digital signal controller from Freescale Semiconductor, at $1.53
These things are kind of a hobby for me. I'm the only guy I know who has a collection of old major appliances, including a couple of 50's washing machines and about three fridges from the 40's. The only thing I don't like about electronics in major appliances is their poor protection from damage due to vibration, temperature, and humidity. They can also be difficult and expensive to replace. (I'm not an expert, but you would think that the need to isolate the circuit board from the environment is what is responsible for difficulty in replacement, but often these boards are put right in harm's way, with very flimsy protection, yet they are still difficult and expensive to replace.)
Look at the low electronics BOM presented here. If that low BOM can be translated into inexpensive replacement, then that appliance manufacturer would have something worth standing in line for. If it can't, then I hope those components have high reliability in that application. Otherwise, I'd say it is unlikely that brand loyalty can be maintained.
Nemos, Indeed, the semiconductor content of many mechanical products has been rising as companies replace some functionalities with electronic drivers. In addition to washing machines, chips are going into dryers, other household gadgets like stoves, microwave ovens and refrigerators.
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Thailand Stages a Comeback Join EBN contributor Jennifer Baljko on Thursday August 23, 2012, at 11:00 a.m. EST for a live chat on how electronic manufacturers in Thailand have shored up their supply chain to reduce the impact of future natural disasters.
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Microsoft Surface: Potential Winners & Losers What are the implications for the electronics industry supply chain of Microsoft Corp.'s decision to launch its own tablet PC? Join industry veteran and EE Times' systems and OEM expert Rick Merritt on Tuesday, July 3, at 12:00 pm EDT for a Live Chat on this subject.
Join EBN contributor Jennifer Baljko on Thursday August 23, 2012, at 11:00 a.m. EST for a live chat on how electronic manufacturers in Thailand have shored up their supply chain to reduce the impact of future natural disasters.
Peter Drucker famously said "Trying to predict the future is like trying to drive down a country road at night with no lights while looking out the back window." Yet in the razor's-edge world of electronics—with a lean supply chain and just-in-time demands—the need to know the future is vital.
While no one really can accurately predict the future, we can take guidance from another Drucker saying which is the best way to predict the future is to create it.
You've heard the saying "the No. 1 supply chain risk is your people." That hasn't always been the case. But today's complex global supply chain requires a new type of multitalented employee. It's one who understands, finance, marketing, economics, is savvy with technology, graceful with relationships and can think analytically.
Where are these people? Are universities properly preparing the next generation supply chain professionals? How do train your existing workforce for these new, demanding positions?
Brian Fuller, editor-in-chief of EBN, will lead a 60-minute Avnet Velocity panel discussion that will ask and answer these and other questions swirling around today's supply-chain talent challenges.
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