Summit Sponsors BPF Lego Factory Tour

In April 2024, Summit Systems proudly sponsored a highly anticipated tour to the renowned Lego Factory in Billund, Denmark, organised by the British Plastics Federation (BPF). Lego, a company that has been moulding bricks in Billund since 1953, welcomed a group of 35 BPF members from the moulding and packaging sectors for an exclusive, sold-out tour.

A Glimpse into Lego's History and Innovation

Lego, founded in 1932, initially produced wooden toys, including cars, aeroplanes, and yoyos. The company ventured into plastic toys with the arrival of their first injection moulding machine (a Windsor SH) in 1942. The tour highlighted one of the first tools used to mould Lego bricks, providing a fascinating historical perspective.

Commitment to the Plastics Manufacturing Industry

The BPF Lego Factory Tour showcased Summit Systems’ commitment to advancing the plastics manufacturing industry. Mike Jordan, Managing Director of Summit Systems, emphasised the significance of the event, stating:

“Summit Systems loved sponsoring this event as we knew it would give some UK plastics manufacturers an insight into 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 social delegation of interesting and often very amusing characters. It was amazing to get to know people representing UK manufacturers and appreciate what a solid industry we have. Thank you to the BPF team for organising a truly memorable event that we will all remember.”

Key Insights from the Lego Team

The tour provided members with an eye-opening experience of Lego's advanced moulding shop, capable of producing over 1,000 bricks per second. Participants also enjoyed nearly four hours of insightful presentations from the Lego team on topics including:

• Recycling and Re-use

• Industry 4.0 / Digitalisation in Production

• LEAN & Housekeeping Disciplines

• Training & Development

A special presentation by Thomas Drustrup, CEO of the Danish Plastics Federation, offered insights into the overarching strategy of the Danish Plastics Federation.

Lego’s Global Manufacturing Footprint

Lego’s global manufacturing footprint includes factories in Czechia (Kladno), Hungary (Nyíregyháza), Mexico (Monterrey), and China (Jiaxing), with additional factories under construction in the US and Vietnam. The Billund factory alone produces around 20 billion elements annually, contributing to Lego’s total output of approximately 60 billion bricks per year.

A Word from BPF Director General Philip Law

Philip Law, BPF Director General, commented on the value of such tours:

“BPF is uniquely placed to organise tours like this. Our size, with 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. It was also a great opportunity for members to network, make new contacts, and forge friendships. We plan to organise more tours like this, and welcome suggestions for potential locations.”

Positive Feedback from Attendees

Feedback from attendees underscored the tour's success:

• Martin Gough, Sales Director at AC Plastics Ltd, praised the experience as “incredible.”

• Siobhan Parks, New Product Development Manager, appreciated the insights into Lego’s lean practices and recycling targets.

• Carl Walker, Production Director at Spectra Packaging Solutions, highlighted the shared challenges and strategies for sustainability and productivity.

• Bruce Margetts, Managing Director of Bericap UK, commended the tour's organisation and the opportunity for networking.

Looking Ahead

Summit Systems is honoured to have sponsored the BPF Lego Factory Tour, providing UK plastics manufacturers with invaluable insights into Lego's world-class operations. We look forward to supporting more initiatives that foster learning and collaboration within the industry.

For more information on Summit Sponsors BPF Lego Factory Tour talk to Summit Process Cooling