Have you ever wondered where your favorite LEGO sets are made and what makes some factories stand out? Let’s take a journey to China, where LEGO has established a significant presence, and explore the top LEGO manufacturing facilities that are setting new standards in quality and innovation.

Where Is Lego Made: A Guide to Toy Manufacturing for …

Product Details: LEGO sets are produced in five main factories around the world, including Denmark, Hungary, Mexico, the Czech Republic, and China. The Billund factory in Denmark produces around 20 billion bricks annually and is central to European distribution. The Nyíregyháza factory in Hungary and the Kladno factory in the Czech Republic serve the European market. The Monterrey factory in Mexico supports North and South American markets, while the Jiaxing factory in China serves the Asian market. LEGO is also expanding with new facilities in Vietnam and Virginia, USA.

Pros:
– Efficient global distribution by having factories close to major markets, reduci…
– High-capacity production ensures timely delivery across various continents.
– Competitive manufacturing environment in regions like China helps control produc…
– Shorter lead times and efficient distribution due to proximity to key markets.

Cons:
– Logistics and quality control challenges, particularly in regions like China.
– Sustainability challenges in some locations, though LEGO is working to address t…

Sustainability Progress

Product Details: The LEGO Group’s sustainability efforts are outlined in their 2022 Sustainability Progress Report. Key highlights include the introduction of paper-based packaging in Europe to replace single-use plastic, the announcement of two new carbon-neutral factories in Vietnam and the U.S. with LEED Gold certification, and a record year for the Build To Give holiday campaign with over two million LEGO sets donated. The company achieved less than 1 percent of waste from its factories going directly to landfill and engaged over 9.8 million children through Learning through Play activities. They also expanded the use of bio-PE elements made from renewable materials,

now found in more than half of their boxes.

Pros:
– Introduction of paper-based packaging to reduce plastic use.
– Construction of carbon-neutral factories with LEED Gold certification.
– Significant reduction in waste sent to landfills.
– Increased use of bio-PE elements from renewable materials.
– Engagement of over 9.8 million children through Learning through Play activities…
– Record donation of over two million LEGO sets through the Build To Give campaign…

Cons:
– Emissions increased in the near term due to new equipment and increased demand.
– Challenges in reducing emissions while finding alternatives to plastic.
– Higher risk non-conformities identified in 25% of supplier audits.

How to Improve Injection Molding Tolerance in the Toy …

Product Details: The article discusses the improvement of injection molding tolerances, particularly in the toy industry. It highlights that injection molding tolerances can be as tight as +/-0.0005” (+/-0.0127mm) to +/-0.002” (+/-0.05mm), and the minimum roughness can be as low as Ra 0.05μm. Key factors influencing these tolerances include mold design accuracy, the type and grade of plastic materials, forming process-related factors such as temperature, pressure, and time, and external environmental factors like temperature and humidity. The article also mentions the importance of mold stiffness, the distribution of the sprue and gate, and the cooling or heating of the mold[1].

Pros:
– High precision and tight tolerances achievable, making it suitable for demanding…
– Ability to use a wide range of polymers as raw materials.
– Smooth surface finish and high production speed.
– Excellent dimensional control system.
– Professional rapid injection molding services available with precise tolerances…

Cons:
– Tight tolerances require stringent process control measures, high-precision mold…
– Mold wear and deformation can reduce standard injection molding tolerances.
– External environmental factors such as temperature and humidity can affect the t…
– Non-uniform wall thickness and improper storage can lead to expansion and post-s…

Are there factories in China that produce raw LEGO …

Product Details: These machines are designed for producing various types of bricks and blocks, including fly ash bricks, interlocking blocks, and hollow blocks. Key raw materials include clay, cement, stone slag, fly ash, and other industrial by-products. Machines like the AAC Block Making Machine and Hollow Block Making Machine are automated and have certifications such as CE. They offer after-sales services and warranties, typically ranging from 1 to 1.5 years[1][2][5].

Pros:
– Automated production process for high efficiency
– Use of industrial by-products like fly ash and slag, reducing waste
– Certifications such as CE ensure compliance with safety standards
– After-sales service and warranty support available

Cons:
– High initial investment cost for the machinery
– Dependence on specific raw materials which may vary in availability
– Energy consumption is relatively high, with some machines requiring up to 67KW o…

Drill size of 6.5mm from overseas manufactures (LEGO)

Product Details: The discussion revolves around the fabrication of PCBs with specific drill sizes, particularly for holes to fit Lego studs. The user found that non-plated holes of 6.5mm size worked best for consistent fit during prototype runs with OSHpark. However, when using manufacturers in China, the maximum drill size available was often 6.35mm, which was too small.

Pros:
– Using non-plated holes of 6.5mm size provides a consistent fit for Lego studs.
– OSHpark supports drill sizes up to 265 mils (~6.731mm) for plated holes, which c…

Cons:
– Many manufacturers in China have a maximum drill size of 6.35mm, which is too sm…
– Routing out a 6.5mm hole with these manufacturers increases tolerance and may no…

Sustainability Progress 2021

Modern Slavery Statement 2022

Product Details: The LEGO Group’s modern slavery statements and sustainability reports outline the company’s efforts to assess, prevent, and mitigate the risks of modern slavery and human trafficking in their business operations and supply chains. The reports are published in accordance with various regulations such as the UK Modern Slavery Act, the California Transparency in Supply Chains Act, and the Commonwealth Modern Slavery Act for Australia. The LEGO Group adheres to its Responsible Business Principles (RBP), which strictly prohibit any form of modern slavery or forced labor and ensure fair and decent working conditions for all workers involved in making LEGO products.

Pros:
– The LEGO Group conducts regular third-party audits of suppliers to ensure compli…
– The company collaborates closely with suppliers and partners to uphold high stan…
– In 2023, the assessment and verification processes found no forms of modern slav…
– The LEGO Group is a member of the ICTI Ethical Toy program and an affiliate memb…

Cons:
– Despite rigorous monitoring, the risk of modern slavery and forced labor remains…
– Higher risk non-conformities were identified in 25 percent of audits of supplier…

LEGO: The missing bricks in their global supply chain?

Product Details: LEGO produces a wide range of interlocking bricks and other toys, expanded through strategic alliances with pop culture brands. The company also ventures into video games and movies. Key components include ABS plastic sheets, electronics, rubber, and packaging materials. LEGO has manufacturing facilities in Mexico, Hungary, Czech Republic, Denmark, and is building a facility in China.

Pros:
– LEGO has a strong relationship with its suppliers, ensuring high-quality product…
– The company has streamlined its supply chain by focusing on larger retail chains…
– Manufacturing facilities are built close to core markets, allowing for faster pr…
– LEGO has successfully reduced complexity in its product lines, cutting down from…

Cons:
– LEGO faced significant challenges with outsourcing, particularly with the partne…
– The company struggles with improper demand forecasting, leading to bottlenecks i…
– LEGO experiences the Bullwhip Effect, especially during holiday seasons, causing…
– Despite improvements, LEGO still faces issues in meeting demand in certain regio…

The LEGO Group

Product Details: The LEGO Group has been focusing on sustainability across several key areas. In 2023, they increased spending on environmental initiatives by 60% compared to 2022 and plan to double this spending by 2025. They have pledged to reach net-zero emissions by 2050 and have set a science-based target to reduce carbon emissions by 37% by 2032 compared to a 2019 baseline. The company has also increased the use of renewable and recycled materials in their products and continued the rollout of paper-based pre-pack bags in Europe and Asia[1][4].

Pros:
– Increased spending on environmental initiatives by 60% in 2023
– Pledged to reach net-zero emissions by 2050
– Set a science-based target to reduce carbon emissions by 37% by 2032
– Increased use of renewable and recycled materials
– Rolled out paper-based pre-pack bags to reduce single-use plastic
– Reached 9.86 million children through social responsibility and local community…

Cons:
– Some new material grades tested proved unsuitable due to inferior quality, durab…
– Challenges in achieving 100% sustainable materials and packaging
– Ongoing need to reduce waste and carbon footprint across the entire value chain

The LEGO Jiaxing Factory

Product Details: The LEGO factory in Jiaxing, China, is a 165,000 m2 facility that includes molding, decoration, and packaging facilities. It was built to support the growing market in Asia and is designed according to the same modular system as other LEGO factories in Denmark, Hungary, the Czech Republic, and Mexico. The factory started delivering its first LEGO play sets in 2015 and is expected to produce between 70 and 80 percent of all LEGO products sold in Asia. It employs over 1,200 people and features a 35,000 m2 molding facility, a 45,000 m2 packing area, and a 6,500 m2 automated high

bay warehouse. The factory adheres to strict global safety and quality standards and incorporates sustainable solutions such as electric cars, reflective surfaces, and solar-powered water heating.

Pros:
– Reduces environmental impact by minimizing transportation from Europe to Asia.
– Ensures high-quality and safe products by retaining full control of the producti…
– Supports the growing Asian market with localized production.
– Employs sustainable solutions like electric cars, reflective surfaces, and solar…
– Maintains consistency with global production standards.

Cons:
– High initial investment, amounting to a 3-digit million Euro figure.
– Requires significant land and resources, covering 315,000 m2.

Comparison Table

Frequently Asked Questions (FAQs)

FAQs About LEGO Manufacturing in China

Where is the LEGO factory in China located?

The LEGO factory in China is located in Jiaxing, a city in the Zhejiang Province, approximately 100 km from Shanghai. This strategic location helps in efficient distribution across Asia.

When was the LEGO factory in Jiaxing established?

The LEGO factory in Jiaxing was officially opened in November 2016, after a construction period that began in 2013. It started producing its first LEGO play sets for the Asia Pacific region in late 2015.

What is the capacity and role of the Jiaxing factory?

The Jiaxing factory is designed to serve the growing Asian market, producing millions of high-quality LEGO elements annually. It includes facilities for moulding, processing, and packaging LEGO products, and it currently employs around 1,200 people.

Why is the Jiaxing factory being expanded?

The Jiaxing factory is being expanded to meet the strong demand for LEGO products in China and Asia. The expansion, expected to be completed by 2024, will add a new automated high bay warehouse, a moulding facility, and a building for processing LEGO elements, significantly increasing production capacity.

What sustainability measures are in place at the Jiaxing factory?

The Jiaxing factory incorporates several sustainability measures, including the use of electric cars for onsite transportation, reflective surfaces to reduce cooling energy, solar-powered water heaters, and 17,400 solar panels to generate over 7,000 MWh of energy annually. The factory also has a significant area dedicated to greenery to prevent soil erosion.