BPF Takes Members to Lego Factory

16 April 20224

Between the 10th-11th April 2024 the BPF organised a tour to the Lego Factory in Billund, Denmark.  Lego has been moulding bricks in or around Billund since 1953.  The company was established in 1932 and originally manufacturing wooden toys including cars, aeroplanes and yoyos.  The companies first injection moulding machine (a Windsor SH) arrived in Billund in 1942 and the Group were shown one of the first tools used to mould Lego during the tour.

The sold-out tour (capacity was reached a few days after the tour was announced) consisted of 35 BPF members from the BPF moulding and packaging groups.  The tour was kindly sponsored by Summit Systems who also attended the tour.

The tour group outside Lego HQ

The companies who attended were not only able to take a tour of the Lego factory (including an eye opening tour of the moulding shop which produces over 1,000 bricks per second) but were also treated to nearly 4 hours of presentations from the Lego team.  The Lego team provided members with insights on a broad range of topics including dedicated presentations on...

• Recycling and Re-use
• Industry 4.0 / Digitalisation in Production
• LEAN & Housekeeping disciplines
• Training & Development

BPF members were also given a presentation from Thomas Drustrup, CEO of the Danish Plastics Federation on the overarching strategy of the Danish Plastics Federation.

In addition to the Lego factory in Billund, Lego have factories in Czechia (Kladno), Hungary (Nyíregyháza), Mexico (Monterry) and China (Jiaxing).  They also have  sales offices in 37 countries around the world.  Factories in the US and Vietnam are under construction.  Currently Lego produce around 60 billion bricks per year with the Billund factory producing around 20 billion 'elements' (bricks and other parts) per year.

Mike Jordan, Managing Director of the event sponsor Summit Systems said...

“Summit Systems loved sponsoring this event as we knew it would give some UK plastics manufacturers an insight to world class manufacturing on a big scale and we were not disappointed. The BPF did a superb job organising this event and the agenda was so well designed, mixing technical excellence with commercial and cultural innovation. Topped off with a relaxed and extremely social and inclusive delegation of interesting and at times very amusing characters. It was amazing to get to know people representing UK manufacturers and appreciate what a solid industry we have. Thank you BPF Team for on behalf of the group for organising a truly memorable event which we will all remember.”

 Philip Law, BPF Director General commented...

‘’BPF is uniquely placed to organise tours like this. BPF’s size of almost 600 members helps us capture the attention of large enterprises who can be assured of a professional interchange. We learnt a lot and the visit really helped inform the work BPF is currently applying to Productivity and Sustainability. Also as well as  seeing Lego at work it  was a great opportunity for the members to network amongst themselves and I’m pretty sure that many new contacts were made and friendships forged. Particularly post - Brexit I’ve noticed that companies are much more willing to share experiences , partly a reaction to the isolationism imposed by Covid , partly a renewed recognition that we are all part of a UK Plc and sink or swim together. Its also  partly a shared frustration with governments and a realisation that if we want anything doing , at the end of the day we can only rely on ourselves to do it. We plan to do more tours like this. Please give us your suggestions for potential locations’’.

What the members had to say…

“It was an incredible experience to be able to witness first hand one of the top moulding facilities in the world and learn from their amazing team.”
Martin Gough, Sales Director at AC Plastics Ltd

“I thoroughly enjoyed the Lego trip. A Huge thank you to the BPF who made the trip run so smoothly.

Lego shared various overviews of their business including their lean practices and their recycling targets which was applicable to the whole plastic industry. It was great catching up with The Danish Plastics Federation (Dansk Plastindustri) and understanding similar constraints we have in the industry and focusing on tackling these together. Huge Thank you once again to all involved in organising.”
Siobhan Parks, New Product Development Manager

“ I’d like to thank Graeme Craig and the BPF for organising the trip and Mike Jordan of Summit Systems for sponsoring, having an opportunity to see how one of the world’s top plastics manufacturers carry out their business was too good to miss.

The Lego headquarters is a very impressive site reflecting their success but equally matched by the passion on display from all the staff during each presentation. Jesper Kjaersgaard Christensen kept us all in check, on time and well fed throughout the day.  A man who really knows where the company is going and how they intend to get there.

Overseeing factories on this scale is enough to give you nightmares but it’s clear Lego have a strategy they are applying across the world to standardise practices and maximise productivity with people being the focus of this progression.

As a much smaller manufacturer it was fascinating to see the challenges, we face at Spectra Packaging echoed by the team at Lego, Recycling, Energy reduction, Industry 4.0, staff training, lean principles, being a responsible manufacturer, all of which have dedicated teams within the group.  Lego have recognised this as being the key to being a sustainable manufacturer for many years to come.

The manufacturing facility was just as impressive as the headquarters, we saw the processes being put in place with commitment to maintaining productivity and troubleshooting."
Carl Walker, Production Director at Spectra Packaging Solutions

"When the opportunity to visit the Lego factory was offered, we jumped at it. Their reputation for digitalisation and use of technology for a highly complex product range is well know and being able to get a better understanding was a privilege. It did not disappoint. The organisation of the factory was exemplary, as was the organisation of the trip by both Lego as hosts and the BPF as organisers. And thanks also to Mike Jordan and Summit Systems for sponsoring the event. As an added benefit it was interesting to network with other BPF members and exchange thoughts on potential application of learnings."

Bruce Margetts, Managing Director, Bericap UK

 

Photos of the Tour (Note: No photos were allowed in the factory)

Lego experts presenting to BPF members

BPF Director General, Philip Law talks to Thomas Drustrup, CEO of the Danish Plastics Federation

 

Welcome briefing from Mike Jordan of Summit Systems and Philip Law of the BPF