LEGO Automation Examples D. Mikkel Hansen 11/26/12

Overview – Current State Based in Billund, Denmark Founded in 1949 LEGO molding factories in Denmark, Hungary and Mexico 400 billion bricks since 1949 19 billion annually 306 million mini rubber tires per year Complete automation 18 out of 1 million bricks wasted .0018%

Overview – Where, Who, What, When Inside the LEGO factory Class Application: What type of automation is used?

Overview – Where, Who, What, When Sensors AGV Conveyors AS/RS Fieldbus Grippers Networks Etc.

Overview – Costs $8 billion revenue yearly – 3rd largest toy retailer No official data on production costs “Because we have so many specialized pieces, the average cost per piece is difficult to name. For example, a 2x4 Lego brick does not require the complexity to produce as a Lego mini figure or a Lego fence piece. The molds that we use to create Lego elements are very expensive to design and produce.” About 0.42 cent per piece AGV – $100,000+ AS/RS – $5 Million Conveyors – Thousands

Overview – Supporting Technology Mainframe – “the brains of the LEGO factory” CAD systems NX since 2008 Optimization Stress analysis Technicians Programmers

Industry – Application Rules and Limitations Tolerance of 10 micrometers

Industry – Primary Vendors

Industry – Existing/Evolving Standards Themed new sets Star Wars Harry Potter Atlantis Mindstorm LEGO theme park Improving robots Design methods

Application – Technical Paper Collaboration with Mindstorm experts Payment with LEGO sets Piracy of proprietary Mindstorm programming The Dream Factory Link to technical paper

References http://en.wikipedia.org/wiki/Lego http://gizmodo.com/5022769/exclusive-inside-the-lego-factory http://www.dailyfinance.com/2011/08/24/why-are-legos-so-expensive/ http://courses.washington.edu/art483/files/media/Wired%2014.02%20Geeks%20in%20Toyland.pdf http://www.pcmag.com/article2/0,2817,1879915,00.asp http://designyoutrust.com/2011/12/lego-production-factory-in-billund-denmark/