Lego factory

Jun - 18 - 2011

If you are a fan of the same Lego, like us, visit this small town in western Denmark, you will also be in something of a religious pilgrimage.Of course, this is an exaggeration, but this city – home Lego, which is perhaps the most famous toy in the world.We have a unique opportunity not only to visit the headquarters of the company, but also seen near the production process from the inside, and trace the processing and packaging of the famous designer.

The whole process is actually quite simple.Create separate blocks design consists of pouring a liquid plastic into a mold and placing it under the press.Form chilled opens – and in the hands of you have finished brick designer Lego.This is followed by a second, more difficult part of the process – processing, add artistic details and design works.

This is a reception at the headquarters of Lego.Pay attention to the ceiling and chairs – it seems that they are made of bricks of the designer.Nice interior, is not it?

All of Lego are made from the same plastic based on acrylonitrile-butadiene-styrene.He comes to Lego directly from suppliers and then stored in giant silos.Usually it is either red or clear, and the paint for a particular fragment is added to the molding machine.This tank filled with liquid plastic, based on acrylonitrile-butadiene-styrene, with the addition of certain dyes.

This is a molding machine.First, very hot plastic is poured into forms on the right side.It then spreads through the small canals, and then enters the molding area through very small incisions.When cold water is poured into a molding machine, it contributes to cooling of the plastic, and the form is opened, allowing the bricks to fall freely on the conveyor belt.

Currently there are about seven thousand active forms, which are used in the manufacture of Lego.Overall, however, the company’s disposal is more than nine thousand of these forms, many of whom are waiting in the wings on the shelves, as this example.The average shape is nearly seventy-two thousand dollars, the cost of the most complex and expensive totaled three hundred sixty thousand dollars.

Plastic gets into the area of ​​pressing the molding machine.

In this picture we see two of the ellipsoid, which have just been to a compressor area.A few seconds later they would fall on a conveyor belt.

In this picture form for the manufacture of parts of the elliptical shape of the last photo.

The main part of a strategy Lego is that the production was as efficient as possible.This means that manufactured bricks and other elements can then be used in different ways.These blue Circuits can then be used as goals for the tiny figurines as decorations or other items.

Tens of thousands of newly produced fragments of Lego for a few minutes ago had been under pressure.

This is one of the twelve forming “modules”.In each module, or a special room-a production zone, located to the sixty-four workers molding machines, divided into two blocks of thirty two cars each.

Robotic arm, a cleaning waste from the smelting process and manufacture of parts from the molding machine.Plastic will be re-sent to the facility and it will be used already in a very short time.

Basket for waste.

Production at the factory is almost waste-free Lego as plastics are used.However, some created in the process of waste still goes into the trash.

Pipes that plastic on the basis of acrylonitrile-butadiene-styrene enters the molding machine.Noise, which is thus formed, like the noise that would cause billions of grains of rice moving on plastic pipes.

Forming machines are used for four weeks, and then they seize and hold a full thorough cleaning.In the photo we see an employee of the company for this procedure.

Trunk action figures on a conveyor belt.Then attach them to the hands, feet, heads and other additional parts and pieces.

The robot arm casteth figure.

Machine paints the figures by adding them to the face and costume details.

This display shows the weight of a small bag of fragments Lego, known as pre-packaging.Weight should be between 94.9 and 95.7 grams.The weight of this pre-packaging is 94.94 grams, so that it passes the test.However, as the display, five bags were too light, and one was too heavy.But 5354 proved to be things in order.

Preliminary packaging Lego pieces on the assembly line at the end of which they are weighed.

We are now in the department of packaging, most of the details are in the packets that come in containers automatically.But some packages are too large, and they have to shake the hand to parts evenly distributed and packages have become more flat and thin.

Boxes with Lego sets on “Star Wars”.

This machine controls the height of the boxes so they can be closed tightly and the fragments do not fall out during transportation.

Boxes with Lego sets on “Star Wars” in the pipeline.

This machine automatically closes and seals the box of them.

Boxes with Lego sets on “Star Wars” is completely packed and ready for shipment.

This machine takes on two ready boxes and place them in boxes of six.

The employee picks up two boxes, accidentally fell from the conveyor.

In each of these boxes, six boxes of Lego kits on “Star Wars”.

Now, these boxes will leave the Czech Republic, where the fall in the official distribution center Lego.

The employee picks up two boxes, accidentally fell from the conveyor.

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