At DELIVER Europe 2024, the conversation around boosting manufacturing efficiency and sustainability through digitalisation and automation takes centre stage. The focus is on how companies are transforming their shop floors, integrating digital technologies to improve production processes while also reducing environmental impact.

A Global Brand Committed to Innovation

Jesper Toubøl opens by sharing The LEGO Group's heritage—a family-owned business that has stood the test of time, with almost 100 years of history. The company is committed to sustainable practices, particularly in how they are transforming fossil-based products into sustainable alternatives. Their work has earned them accolades, including recognition for their innovative approach to sustainability. The LEGO Group is not just about creating products, but fostering creativity and innovation, inspired by the innate creativity found in children.

Strategic Priorities for Digital Transformation

The focus of the discussion shifts to The LEGO Group's strategic priorities: innovating play and innovating retail. Jesper emphasises the importance of digital transformation and energy efficiency. With a commitment to sustainability, LEGO aims to ensure that by 2032, all their products will be made from sustainable materials. This is part of their larger mission to reduce energy consumption and enhance environmental impact.

Condition-Based Maintenance: Reducing Over-Maintenance

One key area of innovation is their approach to machine maintenance. Instead of adhering to traditional maintenance schedules, The LEGO Group uses AI and machine learning to predict when machinery needs maintenance, rather than relying on set cycles. This shift has resulted in the extension of asset lifetimes and significant cost savings. With thousands of moulding machines in operation, this change has had a profound impact, ensuring that equipment is maintained only when necessary.

Data Democracy on the Shop Floor

A critical aspect of the transformation is the concept of "data democracy." LEGO aims to ensure that data is accessible to workers on the shop floor, empowering them to make informed decisions. By integrating smartphones into their operations, they provide workers with intuitive devices that deliver real-time data on machine performance, issues, and maintenance needs. This move has proven to be highly effective, increasing worker efficiency and reducing time spent on tasks like quality inspections.

Enhancing Quality Control with Digital Tools

In addition to improving maintenance processes, the company has focused on refining their quality control procedures. Through the use of apps and algorithms, they now have a system that allows workers to conduct quality inspections in a more efficient and targeted manner. Rather than performing routine checks at fixed intervals, the system adjusts the inspection schedule based on the quality of the samples. This approach has led to significant improvements in quality control and resource management.

Conclusion: A Commitment to Sustainability and Innovation

In closing, Jesper Toubøl highlights the transformative power of digitalisation and automation in driving efficiency and sustainability in manufacturing. By integrating advanced technologies, the company not only boosts productivity but also sets a benchmark for future innovation in the industry. Jesper's passion for continuous improvement and sustainability underscores the broader trend of leveraging technology to create a more efficient and environmentally conscious manufacturing ecosystem.

This session is a testament to the power of innovation in both optimising operations and advancing sustainability. Through digitalisation, companies can unlock new possibilities for growth, efficiency, and environmental stewardship, paving the way for a more sustainable future.