Why your Legos are as addictive as your iPhone

The Lego Movie may have been a blockbuster film, but there’s a lot more behind the toymaker’s success. · Fortune

Many traditional toy makers are having a tough time as competition intensifies from digital games, but Lego is one toymaker that stands out, as the industry saw last week when it posted strong earnings growth for 2014. Sure, having a global blockbuster film in your name is good for business, but to look at Lego's historic, record-breaking 2014 and point only to The Lego Movie would miss much about the longer term success and uniqueness of the company. Even CEO J?rgen Vig Knudstorp, after singing "Everything is Awesome!" at a press conference announcing profits of $829 million (15% over last year's all-time high), said that "without The Lego Movie we would have continued our growth trajectory." What month/date/year was this press conference?

And what a trajectory. Last year, Lego added 893 employees, opened new offices in Shanghai and London; it passed to become the top toy manufacturer in the world, and is now ranked "the most powerful brand" in the world (previously held by Ferrari) by the consultancy, Brand Finance. As Knudstorp pointed out, much of Lego's market--like many other companies is in China. The movie didn't even screen in China. "The fact that it didn't play there means that our more than 50% growth rate in China was helped by the general strength of our marketing and assortment," he said. "The movie is an important event but it is far from the only explanation.

It has not had a recall in more than a decade

One explanation is efficiency. The company's operating margin was 34% last year, which is extraordinarily high, particularly when you consider: it makes plastic and brightly colored bricks. Lego probably has the world's most efficient operating model. Its logistics are unparalleled. When you buy a box of Legos, no matter how large or small, every brick comes with a numeric code, etched inside. If there is ever a missing piece, or a piece that does not fit, Lego will not just send out a replacement immediately, but track down exactly what went wrong in its manufacturing and supply chain, and where.

The cost savings of such relentless error tracking is monumental. Lego hasn't had a single product recall in more than half a decade. Few, if any, companies have successfully competed with Lego, because few companies can approach Lego's level of efficiency or manufacturing precision. This is fairly well known. But the real, unheralded secret to Lego's success is the company's deeply serious study of play.

Most toy companies--like all companies--conduct market research by sending out surveys and forming focus groups. Lego sends people out into the world to study kids in their natural habitat. It is the largest private sponsor of play research, globally, through its Lego Foundation. Play is simply part of the company's DNA (the word Lego is an abbreviation of the Danish "leg godt," meaning "play well"). Lego has attacked the question of why we play from many angles, including watching subjects' brains at play under an MRI, to see which parts light up in different ways, when playing with different toys.