Case Study: LEGO
Essential Idea:
Leveraging production methods to achieve high quality
Introduction
Part of LEGO's success is due to its leveraging of Lean Production and Computer Integration Manufacturing (CIM) to maximize quality.
These videos provide an insight into how the bricks are made.
Manufacturing Process
Most bricks use the injection molding process.
ABS granuals ABS plastic is heated and injected into molds.
The plastic is cooled for about 7-10 seconds in the mold and then ejected.
LEGO's switch to Bioplastics
About LEGO elements made from plants
Polyethylene elements are 1-2% of the total amount of plastic elements produced by the LEGO Group; The sustainable product range covers LEGO® botanical elements such as leaves, bushes and trees made entirely from plant-based plastic.
Plant-based polyethylene used in LEGO elements is made from ethanol produced from sugarcane.
The sugarcane used is sourced sustainably in accordance with guidance from the Bioplastic Feedstock Alliance (BFA) and is certified following global standards for responsibly sourced sugarcane.
All suppliers must comply with the LEGO Group’s Code of Conduct, which specifies strict requirements for ethical, environmental and health & safety standards based on leading global guidelines.
The LEGO Group works closely with its suppliers to ensure life-cycle assessments are conducted, which map the environmental impacts from the production of the bio-based material.
Source: LEGO
Questions
Identify the sustainable design strategies that LEGO is applying in switching the type of plastic it uses in its product.
Describe the social, environmental, and financial benefits of making this switch.
Describe the advantages of using a bioplastic over ABS in the manufacture of LEGO bricks.
Quality Control and Management at LEGO
LEGO is renowned for its quality control. Using complex processes and empowering workers, it has created a workplace that prioritizes quality.
Some QC and QM facts about LEGO
Molds are manufactured to very high tolerances and very accurate. Tolerances are 0.001 millimeters, to ensure they connect.
defect rate is 18 bricks / 1,000,000 manufactured.
Every brick made is to connect with bricks made as far back as 1958
Each element of the product, from bricks, assembly manual, to packaging, is put through testing.
LEGO products carry the EU CE label and meet European Toy Safety Directive regulations; they also meet US Code of Federal Regulation, Consumer Product Safety Improvement Act (CPSIA) and ASTM F963 standard.
Questions
1. Explain how the high tolerances in the manufacture of lego bricks is also a defining feature that differentiates Lego brand bricks from others.
2. Identify if Lego uses a JIT or JIC production system. Describe the advantages and disadvantages of this system.
3. Describe the production systems you see in the video. Outline why this type of system is advantageous in the production of lego bricks.
4a. Outline the steps of the injection molding production technique that is used to manufacture the bricks.
4b. List some design for manufacture considerations that a designer might consider when using this technique.
5. Explain how Lego has used CIM (Computer Integrated Manufacturing) in the video. Describe the advantages to using this type of system?
6. Identify the type of plastic used in the manufacture of LEGO bricks. Outline how its physical and mechanical properties are suited to the manufacturing of LEGO bricks.
7. Outline ergonomic considerations that a designer might consider when designing a LEGO piece. What considerations would they consider when designing a LEGO set?
8. LEGO bricks connect with every other brick made. List possible design specifications that would allow this to be possible?
Analyzing for Innovation
LEGO has leveraged manufacturing systems to be the dominant leader in the "interlocking brick" market for toys. The advantages of interchangeable pieces and components allow LEGO pieces to be assembled and re-assembled in infinite combinations.
Design challenge:
How might the concept of interlocking/inter-changeable system be applied to another product category?
Resources
How LEGO bricks are made; How Stuff Works: detailed discussion of the manufacturing process.
How Lego Makes Safe, Quality, Diverse and Irresistible Toys Everyone Wants: Part Two; Forbes Magazine: Discussion and interview with LEGO designers and marketers. Valuable insight into how LEGO collaborates with IP partners.
How Lego Leveraged A Toy Quality Management System For Improved CSR: Short article detailing how LEGO use QMS to develop and innovate sustainable solutions.
Quality control at LEGO: LEGO Group website.
