Who are we. Engineering & Quality. Elements & Moulds. Verification. Approx. 800 employees. Approx.330 employees. Approx. 26 employees.

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2 Who are we Engineering & Quality Elements & Moulds Verification Approx. 800 employees Approx.330 employees Approx. 26 employees Management Zeiss Manual Calibration Specialists 2012 The LEGO Group Page 2

3 Reorder Novelties Ramp up, Production Elements & Moulds Part Design Mould Design and Manufacture Mould Procurement Mould Qualification Verification Polymer Technology 2012 The LEGO Group Page 3

4 Verification Verification is part of Elements & Moulds in Engineering, based in Denmark. We ensure the safety & quality of our LEGO bricks according to LEGO standards, so our costumer will get the safest & best building experience with the worlds highest quality construction toy. We perform CMM (3d Coordinate Measuring Machine), manual measurements & functional tests to assist our stakeholders in approving new moulds for injection moulding. We are responsible for supplying our factories globally with test & CMM programmes and measuring foundations for inspecting LEGO bricks. Master Calibration, which is part of Verification department, performs calibration of all measuring equipment in Denmark, and supervises the calibration world wide. Verification drives global projects, innovation, and ensure the alignment of foundation of quality in the knowledge in the field of metrology at all our sites. Our mission is to be a globally present knowledge center, consistently supplying high quality metrology solutions, knowledge, guidelines, and to be the preferred partner the natural choice within LEGO metrology The LEGO Group Page 4

We perform CMM (3d Coordinate Measuring Machine), manual measurements & functional tests to assist our stakeholders in approving new moulds for injection moulding.

5 Verification Tasks Measure dimensions on bricks produced for mould approval Test function with and without values on bricks for mould approval Develop, create, and distribute programmes and fixtures for metrology equipment for global use Metrology support on Mould parts Maintain and develop measuring templates and instructions for all sites Contribute with metrology knowledge in innovation projects and development of global standards for metrology Contribute to optimisation of specifications Metrology support for all sites Contribute to optimisation of specifications Administer all metrology calibration at LEGO and perform calibration in Billund Perform MSA on measuring equipment Perform maintenance on measuring equipment Innovation drivers in the field of metrology Quality audits and metrology assessments 2012 The LEGO Group Page 5

projects and development of global standards for metrology Contribute to optimisation of specifications Metrology support for all sites Contribute to optimisation of specifications Administer all

6 Equipment Equipment / Model Range Manual equipment (Height gauges, Micrometer, Pin gauges, etc.) Mahr optimar mm/0,0001 Mahr linear mm/0,0001 AFG 50N Nikon MM-800 Ø300 (300*300) Zwick/Roell z N /1000mm Mecmesin multitest 2,5 500N/400mm Nikon VMR *600*100 Mettler PM g/0,001 Mettler Toledo 800gr/0,01 Mettler 4000gr/0,01 Mecmesin vortex I 30Ncm PS test equipment 2012 The LEGO Group Page 6

Zwick/Roell z005 500N /1000mm Mecmesin multitest 2,5 500N/400mm Nikon VMR6555 600*600*100 Mettler PM480

4 μm Measuring range X, Y, Z = 700, 1000, 600 mm ZEISS MC 550 Vast XT Length measuring

7 Equipment ZEISS Contura G2 /w. RDS/Vast XXT Length measuring error E L,MPE =2.5+L/250 Probing error size E P,MPE =2.4 μm Measuring range X, Y, Z = 700, 1000, 600 mm ZEISS MC 550 Vast XT Length measuring error E L,MPE =3.6+L/200 (L in mm) in μm Measuring range X, Y, Z = 500, 800, 500 mm (MPE E according to EN ISO ) 2012 The LEGO Group Page 7

8 Innovation & Development CT LEGO criteria's: - Scan time: 25 min. (Max. 1,5 hours). - Accuracy for scan: 8µm. - Target measuring volume 70mm x 70mm. - Minimum circumscribed / Maximum inscribed principle for diameters. - No averaging allowed. Cannot use average values for calculation to achieve the desired result. - The accuracy must be achieved in one scan, not multiple scan to achieve target. - CT scanner needs the ability to be able to be 100% automated with Robot attached. - LEGO strategies have to be used, or approved by LEGO, to ensure that the building function is preserved The LEGO Group Page 8

Cannot use average values for calculation to achieve the desired result. - The accuracy must be achieved in one scan, not multiple scan to achieve target.

9 Innovation & Development CT Max difference compared to CMM: 29,1µm = ±14,55µm Measuring equipment at LEGO is allowed to use MAX. 20% of the Tolerance band. Calculated tolerance: 5 x 29,1µm = 145,5µm =0,1455mm = ±0,07275mm So we can use CT for approval of LEGO elements, when the tolerance band is above: 0,146mm or ±0,073mm Conclusion: The CT equipment tested didn t fulfill our criteria. CT technology is not suitable for Minimum circumscribed / Maximum inscribed principle, because of the digital noise, at least not without adding a powerful filter, that will modify the actual feature. CT is good for research and analysis, but from industrial point of view there is a long way for fast and accurate CT measurements. We will still follow the technology and still do test on CT equipment, we need to search further to find the equipment and solution that will fulfill LEGO s criteria and demands. CT is really good for analysis and research, maybe the technology just isn t ready for LEGO. LEGO strategy has been used to perform the measurements in this test. By a reduction of volume / elements or by changing the strategy, the comparison between CT & CMM can be improved. It s the combination of volume, accuracy and strategy that, in this moment, is not possible to achieve The LEGO Group Page 9

10 Elements & moulds 2012 The LEGO Group Page 10

11 Elements LEGO facts: Over elements produced a year active elements 2012 The LEGO Group Page 11

Element 2x4 brick 83 features to be measured on CMM & Manual 2656 features totally on 32 cavities Outside/inside length Outside/inside width Knob-to-edge distance Tube center-to-center

12 Element 2x4 brick 83 features to be measured on CMM & Manual 2656 features totally on 32 cavities Outside/inside length Outside/inside width Knob-to-edge distance Tube center-to-center distance Wall thickness Height Inside / Outside diameter Relief Function test Clutch power Building test & Product safety test Info: Tolerances: 0,01 mm 0,1 mm 2012 The LEGO Group Page 12

center-to-center distance Wall thickness Height Inside / Outside diameter Relief Function

13 Mould insert 2x4 brick Over 500 features to be measured on the mould insert itself. Over features totally on 32 cavities Outside/inside length Outside/inside width Knob-to-edge distance Tube center-to-center distance Position / Parallelism Height / depth Inside / Outside diameter Angles / Relief Surface roughness / Roundness Flatness Width Etc. Info: Tolerances: 0,005 mm to 0,05 mm 2012 The LEGO Group Page 13

distance Tube center-to-center distance Position / Parallelism Height / depth Inside / Outside diameter

14 The connectors 2012 The LEGO Group Page 14

15 The connector 2012 The LEGO Group Page 15

16 Verification -> Production sites The link from the mould to the verification of elements to the production. Instructions for measurement of the features in the mould / LEGO Standard & GPS All measuring methods have to be reproduced and supported at production sites. GIA CS & TS Global Inspection Appendix. Instruction on all M-codes. Instructions on all equipment. Different methods have to be comparable, and linked to the LEGO standard and support the LEGO building system. Extensive Training & Learning concept TWI - Training Within Industry Quality -> lead time Over elements produced a year active elements active and controlled inspection appendixes The LEGO Group Page 16

GIA CS & TS Global Inspection Appendix. Instruction on all M-codes. Instructions on all equipment.

17 2012 The LEGO Group Page 17 Questions???

Removing chips is a method for producing plastic threads of small diameters and high batches, which cause frequent failures of thread punches.

Removing chips is a method for producing plastic threads of small diameters and high batches, which cause frequent failures of thread punches. Plastic Threads Technical University of Gabrovo Yordanka Atanasova Threads in plastic products can be produced in three ways: a) by direct moulding with thread punch or die; b) by placing a threaded metal