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I always thought the extra pieces were there because they were the ones most likely to be lost on the builder's floor, or broken in the case of the laser bolt projectiles.

The packaging process is the one that I find most fascinating, because each set has so many different components. We never get to see where or how the instruction booklets are printed; are they printed off-site or on-site? Do they ever run out of instruction books and have to delay the entire production line? This is also the step where machines are currently being swapped out for recyclable paper bags, replacing the single-use plastic bags. I would love to see where the paper bags are made. I also wonder how many different sets a LEGO packaging facility manufactures at one time, and if all the factories make all the sets, or some facilities specialize in certain sets. Do they spend an entire day (or week, or month) just packaging a few set until there is a huge inventory to ship out, then switch to different sets, do they have one assembly line for each set, or do they vary how many assembly lines are dedicated to each set based on demand? What do they do with canceled sets that were already in production, like the Technic V-22 Osprey or Overwatch 2 Null Sector Titan?

Imagine being a LEGO designer. Could there be more of a dream job.

As a Dane, I find it really cool that despite LEGO being so international, the main production still takes place in my home country.

Great video! I'm not a hardcore Lego guy but I've played with them my entire life. I'm always amazed how I've never bought a single set that was missing a piece. Not once. The level of quality control in Lego is second to none.

One of my favorite sets (and the most recent one I got) is the LEGO Moulding Machine (40502) which is only found in LEGO House in Denmark. I was a lucky duck and got it fairly cheap from Bricklink!

Pretty amazing how the automation works in this factory, its essentially possible with a few mouse clicks to create a new set and the robots grab all the various parts from the inventory and bring them all together!

Meanwhile in a LEGO City family home: "Dad, where do babyfigures come from?" "Son, it's time you finally learn..." *shows this video*

Setting the price before designing the set makes sense for smaller sets and themes, but it results in big problems for larger sets like the Tabletop Football set and the UCS Hulkbuster, where the sets are unnecessarily padded to meet the price point.

Huh. I always just assumed they gave you "extras" of the smallest, most commonly LOST pieces just in case you lost one. But this explanation makes way more sense given the seeming randomness of the pieces and their numbers.

I love this channel because it’s like a Lego version of google

The only time I had pieces missing from a set there were two pieces included that were nowhere in the set at all, one was a small window which was kinda cool. Thankfully LEGO will send you replacements if you’re honest about it. I really like the bag the replacement pieces come in, it’s labeled like a set.

What I'm really interested in is a closer look at the double-molding process some LEGO elements have these days. I've never seen anything else quite like it.

5:59 old ones were made in ABS but in 2015-ish they swapped to PVC which is still good but less prone to break like old Bionicle parts which were made in ABS

I love how they invite kids to play with the sets

Im currently building the Discovery space shuttle set and I was amazed by how do this sorting process works, the correct pieces on the exact bags. Even as an engineer myself it is crazy for me to think the proces is automated...

I work in Injection molding for the auto industry and love seeing closer looks at how the tech is used in other industries

I always wondering if lego sets were designed physically or in a custom cad program. Thankyou for answering that. I guess when it comes to things with alot of small cheap universal parts physical is best. Though i do like the idea that lego is one of those toys that you dont really have to grow out of if your creative. True action figures have an age limit because they are usually based on a tv show made for kids but lego sets are 3d pixel versions of model sets thats only limit is your wallet and creativity.

1:40 that image is beautiful the haunted house and imperial flagship casually sitting next to each other!

I hate they give extra pieces without telling us it is extra. It always confused me thinking I missed placing the piece

I always thought the extra pieces were in case we lost one. I always wondered how they decided which ones were most likely to be lost. 😂

This is exactly what I want to do later in life. It’s a dream job for me, and I’m chasing that down and will find a way in some how. I feel like I would never not be happy in this place of work. I hope I get there one day.

It's amazing and I really love legos. In my closet, I have a half of wall filled with legos with drawers and I divided my bricks. For example, arches goes in the arch drawer

I wonder what are the requirements for a new piece to be approved for production. I mean, a new piece requires a new mold and storage and it's going to be used in just one set until the designers use it again in the future so i guess someone has to approve it or tell the designer to use a different solution.

For me as now adult who loved legos as a child, it’s all about unique parts. If a set does not have unique parts in most cases it’s not worth buying cause it can be made just looking at a picture of it. But sets with unique parts are always high demand. Especially unique canopy or colored glass wall pieces. The biggest disappointment has been not being able to get certain parts in quantity outside of certain sets for unique building opportunities.

I love extra parts cause I can use them for Mocs but they are rarely ever good extra bricks

😏😆how many times my bedrooom floor looked just like that🤣, 4am rootin thru my LEGOS, while parents were sleeping😂

Ninjago sets come with extra weapon pieces, which I really like

LEGO is probably the greatest toy ever developed, playing a part in the childhood of many a person out there. An extremely creative toy that encourages thought and experimentation in the developing mind. Having actually worked for this company some years ago, much as I found it interesting to be part of the LEGO world it was also an eye-opener ..... The Danish company are heavily into psychology and the their angle is that everyone within it should be a big happy family... Nice in theory (if not a little creepy and 'Stepford') but sadly didn't actually work in the UK. Another little known fact about this company is that they NEVER fire anyone..... They just make your life so difficult that you just resign (no HR to speak of back then). Having been part of the original UK LEGO team, it became apparent that their magic formula didn't translate particularly well over here, mainly because their selected management were completely unsuitable and made some staggeringly bad decisions with regard to staff employment - Narcissist's and bully's do not make great co-workers! It was so bad that I left the company on my own terms. It great shame really, as it soured something that I had a great fondness for. LEGO have now sunk to deeper depths by heavily relying on income from licensed Disney models at ridiculous prices....

Lego needs to get back to creativity or "Make it Your Own. The manuals are just detailed guides." "Use these manuals to help create your own masterpieces."

I didn't know about the hidden side line. It looks cool.

I’ve always been curious how they did all this. Thank you

its crazy that some people will make something that isnt a set from pieces they either ordered from their site or found at a garage sale like the fly scotsman steam locomotive and others ive even seen one where someone makes a working car which was cool

Fun fact the building that where they do there brainstorming has a maximum security protocol. "If a visitor is spotted with eyesight. All of the windows closed that are made of steel. All the doors are locked and blacked out" after some time the building will unlock....

For precision of the machinery it's often stated Lego is an even more demanding customer than medical or military.

sometimes the extra pieces are something that isnt used in the set at all. This always perplexes me. :)

man sounds like working at lego seems fun

Love my sets I collect Lego friends sets I’ve around 80 so far just building the new art school and purchased the tiny house today also. Absolutely love the Harry Potter series also but I love the small accessories with the friends sets even as an adult

One of my last sets I got came with a extra 2x5

What a change from the beginning as shown on "The Toys That Built America", Season 2 Episode 4.

This makes me want to work for lego

I always thought that extra small pieces are added on purpose, as those are the most likely to get lost due to size. But it looks like it's due to the machine's accuracy. Interesting. :)

As an automation design engineer, I would absolutely love to tour their manufacturing facility!

being a lego designer is my dream job

Now THAT was astounding..................................

Working at an amazon fulfillment center its crazy to see the small similarities through the process because they are both using so much robot automation

been loving watching these videos. really well put together

I’d say Lego is the most famous toy on the planet❤

3:00 I have a similar setup at a much smaller scale. I have my entire collection sorted by piece in around 30 tackle boxes and a few bins for larger or more common pieces. I have custom labels printed on each box and have them numbered with a master document showcasing all the pieces. Its a nightmare to disassemble sets/creations. I hated it when I was younger as it stifled play. Now that I am older I appreciate it as it makes it easier to reassemble nostalgic sets in my collection and far simpler to find specific pieces when building a stop motion set.

LEGO is so awesome. I always wondered how the sets get put together. The organization of everything is insane.

This was an astounding video, thank you so much ^^

This is super good information for people that want to collect Legos

Every LEGO enthusiast's dream: ENDLESS LEGOS!

personally, if i just got to work in the back-end part of the jobs (like molding, packaging etc.) i would be very happy cuz its lego!

once on bricklink a piece was being sold and it was rare because it was a transparent glitter purple instead of pink

I'm just a kid but when I grow up im going to inspire people with my creations!

I saw the original Death Star droid being made. That means that video was from around 2008-2011.

This is so interesting! I love Lego! I also wrote a book called Heroes Rise: Kingdoms Restored and if it, one day, becomes a movie, Lego would probably (I don't know) make my book, (and/ if one day, movie) characters into Lego and that would be fun to see the Heroes Rise characters in person! Great job on the video, too!

A shark with a freakin' laser beam!

Wow this is seriously mind blowing!! Honestly the first video I watched to actually explain properly how lego is made!! 👍

Those designers have an amazing job

i miss the early lego technics pneumatic sets, i used to have a truck with a crane on the back that you could operate with pneumatics. if i ever have the chance to buy the same set i buyt it

I once got a Lego off road crane (42082) and it was missing a little bag because they gave he an extra rim

Watch as he waves his hand through the Lego. That’s how I find my Lego pieces. 2:13

That’s surprisingly advanced for a company just making a child’s toy. I’ve seen industries where the product failing can kill people put leas care into the finished product.

I woulda assumed the Innovation House would have been a bit more colorful lol

When I was a kid I got lego a lot, as you do, however there was a string of 4 sets I got over a year and each one had missing parts. Thank god you can just tell them and they will send replacements for free. One of the times it was 2 whole bionicle feet

7:45 That's the machine that adds the scratches to all the windshield pieces.

I remember watching some of these clips in orientation. Crazy but fun

first few years working there all you do is put the pieces back in the correct places in the drawers.

You forgot to mention that those ABS Plastic Granules also come in transparent as well

AHH the SOUND of all those pieces☺🤣

Yep, I’m going to work in Lego now, goodbye guys, see u in 10 years when I work in Lego as a designer

3:55 "LEGO's incredibly high standards"?? And how do you explain that they release a desaster set every now and then? (example: 42125 Ferrari 488 GTE) This is far far far far away from a "incredibly high standard" to be honest.

EYYY!! COOL to see Ancotrans presented in this video! I Drive for that Company and have delivered severel loads og pellets to Lego Billund :D SO NICE THAT IS ACTUALLY COOl

Great video. Thank you!

Always wanted to know how our beloved LEGO sets are made! 🙏 Thank You So Much SpitBrix for the short tutorial! 🌷🌿🌏💜🕊🇩🇰

It's good to know that with all the hatred in the world, That we can still rely on Lego to brighten up our day.

I love Legos!! 😸💗

LEGO Denmark actually produces around 100.000 bricks per minute, over 53 billion bricks in Billund alone per year. 1.700 a second. 6 million an hour 144 million a day.

the ocean clean up should help lego with all the plastic pellets they are making

I always thought the extra pieces were in case you lost them since they're so small

I think they just added a few feelgood stories into the doc;) nonetheless, good vid

Not so secret now.

This is fascinating and all. But nevertheless Lego’s designs are getting worse, prices are getting insanely high, they appeal more to the now grown-up kids from the early days than to their initial DNA

Detail, quality and consistency. If it’s supposed to be good quality, then why in the world or the brown bricks so weak

This is my heaven.

Make another Ninjago blind bag opening

Thanks for the video that was awesome 😊 Honestly though at the end watching I was wondering why the final packaging step wasn't automated as well. Seems like all the steps along the way were much more complex and were handled with automation as well just fine.

The "extra piece" statement is not true. LEGO only adds one extra small piece to the first bag in the set to feature that piece. The only exception is if the build is separated into several boxes (like the Titanic, Technic Bugatti, etc.). Then in each box an extra small piece is added to the first bag featuring that piece. These are added because small pieces are easily misplaced or lost when dropped on the floor. The fact that every other bag has the exact number of pieces needed shows LEGO is more than capable of providing the exact number of pieces. It's much cheaper to add a few extra small pieces in a set than having to send dropped or misplaced pieces to customers to allow them to complete the set. It's good business sense.

So all the pieces from a given set will come from the same factory? That would mean needing to make sure the right factories have the right molds before having it build a set with pieces that factory hasn't had before

what a job that must be

I actually have a set that is missing two pieces of one kind to build the specific project. However there are four extra pieces that has nothing to do what the set is all about. I thing sometimes their QA computer makes mistakes. I don't mind, since I only build it once and then like to build my own ideas.

Very interesting. Nice video!

That segue to the ad 😂😂😂😂

Still surprised how the sorting machine works. That it checks on weight seems logic to me and it works. What I do not understand, is that sometimes a piece is missing, another piece, not even related to the set is added. This compensates the weight, but it makes no sense how it get into the set at first. Last 15 months this seems to happen more and more. Or, to be fair, until half a year ago. Havent noticed this lately.

I’ve bought 4 larger sets recently and only 1 of them didn’t have pieces missing !! Lego is good though and you just order online the missing pieces and they ship them to you.

I love the medieval ones!

not sure how much of that was secret as much of this info can be found from one of the documentaries about lego