Kladno, Czech Republic

The LEGO Group’s second-oldest production site, we’ve been packing LEGO® sets since 2000. Today, we decorate bricks, assemble minifigures, design and create 3D LEGO models and make LEGO sets that bring joy to kids and adults around the world. We’re also a main center for sustainable packaging innovation.

A closer look at production in Kladno

A lot happens here. We decorate and assemble some of the world’s favorite LEGO characters, animals and vehicles and even box up the finished packs ready to go to stores worldwide. We have a talented team that designs and creates the 3D LEGO models you see in stores and at LEGOLAND® parks. Finally, we have a research and development team focused on exploring and innovating to make our packaging as sustainable as possible.

Logistics
Our three huge, high-bay warehouses store the millions of LEGO elements that we decorate, assemble and pack. In our manual warehouses, we store prepacks which are then packed into final boxes and sent to distribution centers in Jirny, Czech Republic and in Belgium. Our team, which has the highest percentage of women operators of any LEGO factory, keep everything moving perfectly.
Processing
This is where we decorate and assemble LEGO elements, minifigures and animals. We like to think of it as bringing them to life! With 116 assembly and decoration machines, we produce around 1,300 different kinds of minifigures. Every day we process around 8 million LEGO elements and assemble around 1.1 million minifigures.
Packing
There are two parts to our packing area. The first is where we pack elements into prepacks, making sure that not a single element gets missed out. In the second, we pack boxes with prepacks, instructions and smiles. We are the LEGO Group’s largest European packaging site – with 93 prepack lines producing 24 million prepacks each week and around 20 final pack lines producing 4 million boxes per week in the high season.
Maintenance
The team here does an awesome job of keeping our production departments running smoothly. They take care of our machines, solve problems and carry out repairs. They work with all kinds of different technologies and operating systems, and are always on hand to fix production issues as they arise.
Research & Development
Our R&D colleagues are a team of experts who are passionate about exploring new ways to assemble and pack our products as efficiently and sustainably as possible. The team has a global responsibility for all the LEGO Group’s packing equipment, and they lead projects with partners across all LEGO production sites.
Industrial Automation
There’s a lot of technology behind our production processes, and this team looks after it all. They innovate, manage and maintain the hardware and software we rely on – focusing on safety and efficiency. They also play with new ideas and approaches to drive operational excellence and make our production a bit better every day.
LEGO Model Production
Unique things happen here. From initial designs to final installation, our team creates awesome LEGO models that amaze our fans worldwide. They’ve created a 20-ton Star Wars™ X-wing, a life-sized Bugatti Chiron built from a million pieces and a model built to celebrate Disney’s 100-year anniversary. Who knows what they’ll make next?