Date: November 12th, 2003
Cate: Regular

Making of a Brick

Today from Mr. K’s Remainders: A totally cool isometric cartoony explanation of how Legos are made.

Exploring the same site (Pop & Company) a little more, I found this: Super Mini-Games! Justice Leage Super Cubes and Mashi-Mojo are my favorites.

1 Comment

  1. November 14th, 2003

  2. Based on my experience, this little anim is not entirely correct.. I\’ll attach my big explanation email to explain:

    I think they have a more automated factory in denmark, but there are some
    pretty substantial differences between what that little anim shows and what
    went on at the plant I worked at.

    Major differences:

    1) The granules come from trucks, but are stored in big reinforced cardboard
    boxes called \”gaylords\”. A forklift driver would use a forklift to transport
    the gaylords to a staging area, which was cleverly named \”staging area\”. From
    there I would take each gaylord out of staging, and use a forklift to put it
    on a special hydraulic ramp. You had to use a forklift cause each gaylord
    would weigh about 2 tons. Anyway you put it on the ramp, cut it open, and
    there was this gigantic vacuum cleaner that you had to move around manually
    that came down from the ceiling that sucked the granules out of the gaylord
    into the giant 3 story hopper. From there, another system of pumps would pump
    the granules into the moulding machines. It takes about 10 minutes to suck
    one gaylord.

    2) There were no automated moving robots on the moulding floor, although I
    think they were starting to test them out right after I left. Basically,
    after all of the bricks were boxed, I would take a hand truck (no forklifts
    allowed in moulding rooms for obvious reasons) and move the completed box over
    to a pickup area where the bricks would get moved eventually to a warehouse
    where they were later \”decorated\” hahaha and packaged.

    The molding machines themselves were automatic, but there are constant waves
    of people always fixing them, cleaning the filters and pumps, etc..

    The actual process of feeding the granules was pretty manual, and labor
    intensive.. you had to look at every shipment of granules to make sure there
    were no imperfections. lego works like everywhere else, quality control is
    actually impossible, so when you find 1 defect in a batch, you must assume the
    whole batch is defective, and the whole thing gets scrapped. One batch is A
    LOT of legos, like tons of them. I wonder if they\’ve somehow made it more
    automated. I have to think they have.