Apple Uses Tiny QR Codes to Track Display Manufacturing Failures and Cut Costs

Apple etches iPhone displays with small QR codes that let it precisely track the number of defective screens that are thrown out by suppliers, according to a new report from The Information.

iphone 15 sizes
One barcode is the size of a grain of sand and can be viewed only with special equipment, while the other is on the inside of the display along the bezel. Apple spent millions of dollars developing the barcode process and installing laser scanning equipment at Lens Technology and Biel Crystal, two manufacturers that make the ‌iPhone‌'s cover glass.

With this system, Apple has a precise count of every piece of glass produced by Lens and Biel, and an exact read on how much material is wasted due to defects. A source that spoke to The Information said that when the barcodes were first implemented, Apple found that as many as three out of 10 pieces of cover glass were thrown away due to manufacturing errors, and with pressure from Apple, the suppliers have been able to cut that down to one in 10. Because Apple pays for production, lowering error rates has saved it hundreds of millions of dollars.

Apple has used the display barcodes to streamline manufacturing since 2020, and the company is able to see which company made the glass and the date it was manufactured for tracking production level and yield rate. Other ‌iPhone‌ components have had small barcodes to trace defects or find the source of leaks for many years, but prior to the display system, barcodes were primarily used for metal parts.

The Information's full report goes into more detail on the barcode, including the complex, multi-step process that Apple uses to get the barcodes onto the displays.

Top Rated Comments

GMShadow Avatar
9 weeks ago

If these millions of dollars would be invested in QA rather than a microscopic QR code.

Apple found that as many as three out of 10 pieces of cover glass were thrown away due to manufacturing errors, and with pressure from Apple, the suppliers have been able to cut that down to one in 10. Because Apple pays for production, lowering error rates has saved it hundreds of millions of dollars.
This is QA.
Score: 25 Votes (Like | Disagree)
havaloc Avatar
9 weeks ago
It's probably a Data Matrix code, not a QR code.

https://en.wikipedia.org/wiki/Data_Matrix

"The most popular application for Data Matrix is marking small items, due to the code's ability to encode fifty characters in a symbol that is readable at 2 or 3 mm2 (0.003 or 0.005 sq in) and the fact that the code can be read with only a 20% contrast ratio.[1] ('https://en.wikipedia.org/wiki/Data_Matrix#cite_note-1') A Data Matrix is scalable; commercial applications exist with images as small as 300 micrometres (0.012 in) (laser etched on a 600-micrometre (0.024 in) silicon device) and as large as a 1 metre (3 ft) square (painted on the roof of a boxcar ('https://en.wikipedia.org/wiki/Boxcar')). Fidelity of the marking and reading systems are the only limitation. The US Electronic Industries Alliance ('https://en.wikipedia.org/wiki/Electronic_Industries_Alliance') (EIA) recommends using Data Matrix for labeling small electronic components.[2] ('https://en.wikipedia.org/wiki/Data_Matrix#cite_note-Stevenson-2')"
Score: 14 Votes (Like | Disagree)
zilchfox Avatar
9 weeks ago

If these millions of dollars would be invested in QA rather than a microscopic QR code.
Did… did you even read the article before replying?
Score: 14 Votes (Like | Disagree)
Attirex Avatar
9 weeks ago
next level sh*t right there. :D

Apple execs prob have barcodes, too.
Score: 13 Votes (Like | Disagree)
sack_peak Avatar
9 weeks ago
This is a supply chain dream... I am surprised this has not been implemented chain-wide a dozen years ago.

These "waste" may end up being sold as spare parts for unauthorized repairs or be used to manufacture fake iPhones that runs Android skinned with iOS UI & a 30nm SoC.

These fake iPhones proliferate poor nations with weak IP law implementations.

25 years ago LCD TVs sold at $15,000 ('https://www.zdnet.com/article/flat-tv-big-price/').



Today it is under $150.

The price became that low when production yield became that perfect.
Score: 11 Votes (Like | Disagree)
sack_peak Avatar
9 weeks ago

If these millions of dollars would be invested in QA rather than a microscopic QR code.
The QR code acts like an serial # per part/component. Doing that helps automate QA eliminating human error or intervention.
Score: 10 Votes (Like | Disagree)

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