LEGO packs its sets using an automated system where boxes, called cassettes, move under bins containing different piece types, which release the correct number of pieces into the cassettes.
With sets often containing hundreds of diverse elements, the process of packaging must be both rapid and highly accurate. LEGO employs a sophisticated system to achieve this precision and speed.
Here's a breakdown of the core process based on manufacturing insights:
- Automated Movement: Boxes called cassettes roll on conveyor belts underneath the bins that hold each type of piece. These cassettes serve as the containers that will receive the individual LEGO bricks.
- Precision Dispensing: Located above the conveyor belts are bins, each specifically designed to hold a particular type of LEGO piece. The bins open and close to release the right number of pieces into each cassette. This ensures that every set receives the exact components it requires according to its design specifications.
This automated approach minimizes errors and significantly speeds up the packaging of millions of LEGO sets produced worldwide. The system handles the complex task of accurately sorting and distributing a wide variety of small parts into the designated packaging for each unique set.
