Apple - lifecycle of an iPhone - process along the supply chain

The lifecycle of an iPhone along its supply chain involves several key stages, streamlined for efficiency in Apple’s global network:

1. Design and R&D: Apple designs the iPhone in Cupertino, California, focusing on hardware, software (iOS), and components like the A-series chips. This stage involves prototyping and collaboration with suppliers for custom parts.

2. Component Sourcing: Apple sources raw materials (e.g., aluminum, lithium, rare earth elements) and components globally. Key parts like displays (from Samsung in South Korea), camera modules (from Sony in Japan), and chips (from TSMC in Taiwan) are manufactured by specialized suppliers. Over 90% of these suppliers are in Asia, primarily China.

3. Assembly: Components are shipped to assembly plants, mainly operated by Foxconn, Pegatron, and Wistron. Historically, most iPhones were assembled in China (e.g., Foxconn’s Zhengzhou plant), but India (e.g., Foxconn Chennai) now handles 10-20% of production as of 2025. Workers assemble the iPhone, integrating the logic board, display, battery, and casing, followed by quality testing.

4. Distribution: Assembled iPhones are shipped to distribution centers. For the U.S. market, this often involves air freight (e.g., the 2025 airlift from India to dodge tariffs) to regional hubs. From there, they’re sent to Apple Stores, carriers (e.g., Verizon), or retailers like Amazon.

5. Retail and Sales: iPhones reach consumers through Apple’s online store, physical Apple Stores, or third-party retailers. Marketing campaigns and carrier partnerships drive sales, often tied to annual launches (e.g., iPhone 16 in 2024).

6. Use and Support: Consumers use the iPhone, supported by Apple’s ecosystem (App Store, iCloud) and services like AppleCare. Software updates extend the device’s life, typically 5-7 years.

7. End-of-Life and Recycling: Apple offers trade-in programs and recycling through partners like Daisy, a robot that disassembles iPhones to recover materials (e.g., aluminum, cobalt). In 2025, Apple recovered 14,000 metric tons of materials this way. Unrecyclable units may end up in e-waste streams, though Apple aims for a closed-loop supply chain by 2030.