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LEGO factory visit


LEGO factory visit

LEGO factory visitApril 14th, 2017

On April 12 the teams of Innovation department and Continuous Improvement Kaizen team of Printmasters have visited the manufacturing site of LEGO in Nyiregyhaza, Hungary.
• 120.000 m2 on a 100 hectare site;
• Moulding of LEGO DUPLO and LEGO System bricks, DUPLO processing and packing of DUPLO & LEGO System bricks;
• 2.400 employees;
• 768 moulding machines;
• State of the art High Bay warehouses (40.000 pallets + 500.000 boxes);
• Production & logistics in house;
• Flex work & transport is outsourced.
 
 
LEGO builds their strategy on 5 promises: People promise, Product promise, Play promise, Planet promise & Partner promise. LEGO analyzed their existing facilities in Denmark, Czech Republic and Mexico and built in Hungary their best-practice manufacturing site, in modular fashion so easy to extend in future (2018 - 2020). As LEGO is manufacturing DUPLO for children <1,5 year, there are very strict regulations in terms of hygiene and product safety. They have specific corridors and terraces for visitors. Visual management is similar as seen at Audi.
 
LEGO has same seasonality as Xindao, a huge peak just before Christmas. Level of automated processes is high, although LEGO still employs more than 2.400 persons. LEGO copes with same difficulties to recruit, train and retain personnel. Has been nice to share experiences and ideas here.
LEGO uses pad print as the decoration technique, maximum of 5 colors. Plastic used for the bricks is ABS, ink is eco friendly and safe for children. Pretreatment is done with Corona treatment, Post treatment is done with a similar solution Printmasters has implemented this year: Dry2Pack. Total product introduction cycle takes around 2 years at LEGO where all aspects are analyzed, tested and certified.
 
 
 
From left to right: Otto Opincariu (Innovation), Cosmin Lucean (Technical & Innovation manager), Calin Moldovan (Innovation), Ionut Lucean (ICT), Andrei Pintea (DTP / Kaizen), Bogdan Petreus (Operations), Raul Varga (Customer service / Kaizen), Gabriela Danut (Finance), Calin Sabou (pad print), Harjan Boes (Operational Excellence manager), unknown Hungarian Lego guy, Bianca Lupse (QC coordinator / Kaizen and Simona Andrusca (Innovation / Kaizen).

 

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