Scaling Beyond the Spreadsheet: A Case Study in Automated eSIM Lifecycle Management

Written by: Jason Segarra Published: January 13, 2026 Use Cases

Tags: API | eSIM | Event Handler | IoT | Use Cases

In the world of consumer electronics, the gap between a successful pilot and a global rollout of 100,000 units is often filled with logistical friction. For many manufacturers, the hidden cost of IoT isn’t just the hardware or the data – it’s the operational overhead of managing connectivity across the supply chain.

We recently partnered with a global enterprise manufacturer to solve this exact challenge. Their goal was ambitious: a high-volume consumer device requiring seamless transitions from the factory floor to distribution centers, and finally to the end-user’s home.

By utilizing the Soracom platform, we implemented a full 8-phase eSIM lifecycle management strategy. This framework serves as a proven model for any organization looking to scale their IoT deployment.

The Core Framework: The SIM Status State Machine

To achieve true automation, we must move away from the binary “On/Off” thinking of traditional cellular plans. Instead, we view the eSIM as a programmable asset that moves through distinct states. In our case study, we utilized five key statuses to track devices through their complete lifecycle:

This granular control is the foundation of zero-touch provisioning. It ensures that no matter where a device is in the world, its connectivity status reflects its current stage in the business cycle.

Phase 1: Provisioning and Group Assignment

The journey begins before the eSIM even reaches the factory. For our client, efficiency meant handling batches of over 100,000 units.

• The Workflow: As eSIMs are ordered, they are automatically assigned to the client’s account and placed into a predefined SIM Group.
• The Benefit: This “Group” level configuration ensures that every SIM inherits the same automation rules and Event Handlers from day one. By using bulk registration APIs, we eliminate the need for manual “kitting” and move straight to shipping the components to the contract manufacturer.

Phase 2 & 3: Manufacturing and Factory Testing

On the assembly line, every device must be tested. However, a common pain point is the “testing tax” – the data charges incurred just to verify a radio works.

• The Soracom Solution: We utilized Test Mode. When the device connects for the first time, the status moves from Ready to Testing.
• The Logic: Data usage is waived during this phase. Once the manufacturer completes their quality check, a configurable timer automatically transitions the SIM to Standby. This ensures the device is “proven” to work, but no recurring fees are set until the SIMs are delivered to the final user and fully activated.

Phase 4 & 5: Inventory and Distribution QA

After leaving the factory, devices often sit in distribution centers. Our client needed to perform sample-based QA without accidentally triggering a “live” customer status.

• The Framework: Devices stay in Standby (incurring minimal or no costs) while in inventory.
• The Grace Period: If a QA technician powers on a device, the SIM moves to Active. With help from Soracom SAs, our manufacturing partners implemented a “grace period” logic via API; if the device is returned to Standby within three days, the system ignores the connection, preserving the full 2-year plan for the eventual buyer.

Phase 6: End-User Activation

This is the “magic” moment for the consumer. The goal is a zero-touch experience where the device is ready to use immediately upon unboxing.

• The Automation: When the user hits the power button, the status change from Standby to Active triggers a Soracom Event Handler.
• The Webhook: The platform sends a real-time notification to the client’s cloud application, which can then trigger application-specific actions, such as sending welcome messages, running initial user set up, etc. If necessary, the client’s cloud application can also call APIs such as the setExpiryTime API to set customer’s operational period, set IMEI lock and speed class to complete the initial setup

Phase 7: Active Service Period

Once the device is in the wild, the lifecycle management shifts to transparency. Users want to know how much service they have left.

• The Capability: The client’s application uses the getSubscriber API to pull the expiration date directly from the network.
• The User Experience: This allows the device interface to display an accurate “Service Remaining” countdown, ensuring the user is never surprised by a sudden loss of connectivity.

Phase 8: Subscription Expiration and Renewal

The final phase is the most critical for retention. How do you handle a device when its prepaid time runs out?

• The Expiry Action: We configured the system to automatically move the SIM to Suspended the moment the timer hits zero.
• The Renewal Path: If the user purchases an extension, the client’s app simply calls the setExpiryTime API again. If they don’t, the SIM remains suspended for up to a year, allowing for easy “win-back” reactivations without the cost of shipping new hardware.

Why This Framework Matters for Your Scalability

Through this 8-phase journey, we demonstrated that eSIM lifecycle management is more than just a technical feature, it is a business strategy. By using a platform that supports granular SIM states and event-driven automation, our client achieved:

1. Zero-Touch Provisioning: No manual setup at any stage.
2. Cost Optimization: No data charges for testing or sitting in warehouses.
3. Global Readiness: The ability to deploy a single SKU that adapts to the local network and billing rules automatically.

We have seen the headaches that come from trying to manage these phases manually. Moving to an automated lifecycle doesn’t just save money; it provides the operational freedom to focus on building a world-class product.

Would you like to see how these 8 phases could be mapped to your specific manufacturing workflow? We can help you audit your current provisioning process and identify where Test Mode or Event Handlers can reduce your overhead. Let’s start the conversation.