Case Study: Reliance Jio Modernizes SIM Issuance for 5G Launch

Discover how Pack-Smart powered Reliance Jio’s 5G SIM launch, scaling to 1 million cards per day and cutting activation from 12 hours to 15 minutes, all with 100% data integrity.

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Launched September 2016 and rapidly amassed 425 million subscribers as the largest mobile network operator in India.

Overview

When Reliance Jio prepared its 5G rollout, they needed a personalization and fulfillment process that could keep pace with their hyper-growth and unmatched quality standards. Pack-Smart Inc. was selected to automate end-to-end SIM issuance, driving peak efficiency, elevating customer experience, and guaranteeing 100% product integrity.

Challenges

Sky-High Throughput: Meet an ambitious target of 1 million SIM cards per day.

Rapid Activation: Slash activation times from 12 hours to under 15 minutes.

Data Security & Traceability: Ensure flawless ICCID and personalization data management.

Cost & Touchpoint Reduction: Eliminate manual steps that drove up errors and expenses

Solution

Modular Factory Automation: Complete line design for SIM product design, personalization, and fulfillment—built around quick-change modules for future scalability.

SAP & Delta-X Integration: Real-time data exchange with Jio’s SAP backbone; Delta-X Tracker ensured 100% data and product integrity at every station.

Secure IT Network: End-to-end encryption of ICCID and customer data; secure servers supporting traceability audits.

Results

1 Million SIMs/Day: Sustained peak throughput without compromise.

15-Minute Activations: Activation latency reduced by 98% (from 12hrs to 15min).

>99.9% Accuracy: Near-zero field activation errors thanks to automated QC checks.

Touchpoint Elimination: Removed manual handoffs that previously added cost and delay.

100% Product Integrity: Full traceability from personalization through shipment.

Continuing Partnership

Pack-Smart inc. designed ultra-quiet outdoor cellular-tower control enclosures that are now deployed across India. In tandem, we collaborated on an advanced quality-management system for next-generation silicon wafers, bolstering Jio’s upstream supply reliability. Today, we maintain those gains through regular performance audits and ongoing software updates to ensure sustained efficiency.

Conclusion

By partnering with Pack-Smart Inc., Reliance Jio not only hit its 5G launch targets but set a new industry benchmark for speed, security, and scale in SIM personalization. This collaboration underscores how automation and integrated data platforms can transform complex fulfillment challenges into competitive advantage.

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