Reliability-Engineering-in-Mobile-Phone-Manufacturing.pptx

Internship report.

1. Reliability Engineering in Mobile Phone Manufacturing A Summer Internship Experience at Bhagwati Products Ltd. Saksham Vasu Roll No: 61414812724, CST-9, MAIT 15th June 2025 to 27th July 2025

2. Presentation Roadmap Our journey today will cover the crucial role of Reliability Engineering within the consumer electronics sector, particularly in mobile phone manufacturing. We will explore key methodologies, practical case studies, and the invaluable learning outcomes from my internship at Bhagwati Products Ltd. 01 Company Overview & Fundamentals Bhagwati Products Ltd., Quality & Reliability 02 Why Reliability Engineering is Crucial Importance in mobile manufacturing 03 Key Reliability Testing Methodologies How we ensure product durability 04 My Role & Case Studies Practical applications of theory 05 Data Analysis & Tools The science behind reliability 06 Sustainability & Green Reliability Durability as a path to eco-friendliness 07 Customer Impact of Reliability Building trust, safety, and brand loyalty 08 Industry Benchmarks & Standards Global testing protocols and practices 09 Challenges & Future Outlook Innovations and industry trends 10 Key Learning Outcomes Bridging academia and industry

3. Bhagwati Products Ltd. : An Overview Bhagwati Products Limited, a subsidiary of Micromax, stands as a pioneering force in the Indian consumer electronics landscape. Renowned for its commitment to innovation and affordability, Micromax has democratized mobile technology by introducing features such as dual-SIM capabilities and extended battery life to the mass market. My Department: Quality Assurance (QA) My internship was primarily within the Quality Assurance (QA) department, the critical custodian of product quality, performance, and durability throughout the product lifecycle.

4. Why Reliability Engineering is Crucial Reliability engineering is the discipline focused on ensuring a product performs its intended function without failure under specified conditions for a given period. In the dynamic mobile phone market, this translates directly into sustainable success. Figure: The Bathtub Curve of Product Failure Rates Customer Trust: Builds strong brand reputation and loyalty. Cost Reduction: Minimises warranty claims, returns, and repair expenses. Competitive Edge: Differentiates products in a saturated market. User Safety: Paramount for components like batteries and chargers.

5. Key Reliability Testing Methodologies Ensuring mobile phone durability involves rigorous testing across various domains, simulating real-world stresses and potential failure points. Environmental Testing Simulates extreme climatic conditions through temperature/humidity cycling and thermal shock. Mechanical Testing Assesses physical resilience through drop tests, vibration analysis, and bend tests. Electrical Testing Validates electronic robustness, including ESD (Electrostatic Discharge) tests and battery cycle testing.

6. My Role: Reliability Engineer Intern My internship provided hands-on experience within Micromax's professional QA lab, bridging theoretical knowledge with practical application in a dynamic manufacturing environment. Test Execution Setup and meticulous monitoring of various reliability tests, ensuring adherence to protocols. Data Collection Precise recording of test parameters, environmental conditions, and observed failure points. Preliminary Analysis Initial visual inspection, basic disassembly, and forming hypotheses on failure mechanisms. Reporting & Documentation Compiling comprehensive data logs and assisting in the preparation of technical reports.

7. Case Study 1: Battery Life Analysis A critical aspect of mobile phone reliability is battery longevity. This case study focused on predicting battery lifespan and identifying degradation patterns under accelerated conditions. Objective To predict the expected lifespan of smartphone batteries and understand their degradation patterns over time, informing warranty policy and design improvements. Methodology Accelerated Life Testing (ALT) using automated charge-discharge cycling—a technique that simulates years of usage in a shorter timeframe. My Contribution Rigorous monitoring of test cycles. Accurate recording of capacity data at predefined intervals. Assisting in preliminary Weibull analysis to model failure. Figure: Accelerated Life Test Results and Weibull Distribution for Battery Degradation

8. Case Study 2: Drop Test Failure Analysis The drop test is a fundamental evaluation of a mobile phone's structural integrity and physical durability, revealing critical weaknesses under impact. Objective To systematically identify structural weaknesses and common failure modes in new smartphone models when subjected to physical impact. Methodology Controlled drop tests performed from specified heights and orientations, mimicking real-world usage scenarios. My Contribution Execution of drop sequences with precision. Detailed documentation of cosmetic and functional damage. Assisting in root cause analysis for identified failures. Figure: Pareto Chart of Drop Test Failure Modes

9. Analyzing the Data: Tools for Reliability Effective reliability engineering relies on sophisticated data analysis and specialised tools to uncover insights from test results. Weibull Analysis The cornerstone for life data analysis, helping to characterise failure patterns (infant mortality, random, or wear-out) through its shape parameter (β). Pareto Charts Visual tools to identify the "vital few" failure modes responsible for the majority (e.g., 80%) of problems, guiding focused corrective action. Software Used Proficiency gained in Microsoft Excel for data organisation, and exposure to statistical software like Minitab/JMP and specialised ReliaSoft tools.

10. Reliability as a Path to Sustainability Extended Product Life: Maximising product longevity reduces waste and resource consumption. Repairability: Products designed for easy repair decrease the need for replacements. Energy Efficiency: Optimised performance lowers energy usage throughout a product's lifecycle. Circular Economy: Embracing a closed-loop system minimises environmental impact.

11. Why Reliability Matters to Customers Trust & Loyalty Consistent product performance builds strong customer relationships. Safety Assurance Reliable products ensure user safety and mitigate risks. Cost Savings Fewer repairs and replacements translate to long-term financial benefits for customers. Competitive Edge Superior reliability distinguishes products in a crowded marketplace.

12. Global Standards in Reliability Testing IEC & JEDEC Protocols International standards for electronic component testing and qualification. MIL-STD Tests Rigorous military specifications ensuring durability in extreme conditions. ISO 9001 & Six Sigma Frameworks for quality management and process improvement. Micromax’s Adaptation Integrating these global benchmarks into our robust testing methodologies.

13. Challenges & The Future of Reliability The mobile industry's rapid evolution presents continuous challenges and exciting new frontiers for reliability engineering. Emerging Technologies: Foldable displays, 5G thermal management, and new battery chemistries introduce complex new failure modes. Supply Chain Complexity: Managing consistent quality across a disparate, global network of component suppliers. Sustainability Imperative: Designing for extended product life, enhanced repairability, and circular economy principles. AI/ML for Prediction: Leveraging machine learning to predict failures from vast datasets. Digital Twins: Creating virtual replicas for real-time simulation and predictive maintenance. IoT Field Data: Utilising real-time performance data from deployed devices for continuous improvement.

14. Key Skills & Knowledge Gained Technical Skills Hands-on experience with environmental chambers, drop testers, and advanced data analysis (Weibull, Pareto). Practical Knowledge Deep understanding of mobile phone failure modes and Quality Assurance processes (IQC, IPQC, FQC). Professional Skills Precision in data recording, systematic problem-solving, effective teamwork, and professional communication.

15. Bridging Theory and Practice This internship served as a crucial bridge between academic theory and the practical realities of real-world manufacturing, providing profound insights into the product development lifecycle. The internship provided a practical understanding of how theoretical knowledge from university translates into tangible solutions in a manufacturing environment. Reliability Engineering is a critical, data-driven function, directly impacting product quality and ultimately, customer satisfaction. Every decision is backed by rigorous testing and analysis. This invaluable experience offered deep insights into the end-to-end process of building a reliable consumer electronic product, from initial design considerations to final quality checks.

16. Internship Certificate

17. Thank You