All language subtitles for How.Its.Made.Dream.Cars.S04E02.1080p.DSCP.WEB-DL.AAC2.0.H.264-NTb

Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"

THE CHEVROLET CAMARO...

A LEGENDARY MUSCLE CAR
TRANSFORMED FOR THE MODERN ROAD.

-- Captions by VITAC --
www.vitac.com

CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS

THE YEAR WAS 1966.

GENERAL MOTORS
WAS HOLDING A BIG EVENT

AT A HOTEL IN DOWNTOWN DETROIT.

FOR THE FIRST TIME IN HISTORY,
14 DIFFERENT CITIES

WERE LINKED VIA PHONE LINES
FOR A LIVE PRESS CONFERENCE.

IT WAS THERE THAT
GENERAL MANAGER PETE ESTES

ANNOUNCED THE BIRTH
OF A NEW CAR LINE... THE CAMARO.

THE NAME WAS INSPIRED
BY THE FRENCH WORD "CAMARADE,"

MEANING "GOOD FRIEND."

THE VEHICLE WOULD GO ON

TO BECOME ONE OF THE MOST ICONIC
AMERICAN MUSCLE CARS EVER BUILT.

THE CAMARO IS SOMETIMES
CLASSIFIED AS A PONY CAR,

MEANING AN AFFORDABLE
BUT STYLISH

HIGH-PERFORMANCE VEHICLE.

HALF A CENTURY AFTER ITS DEBUT,

CAMAROS ARE AMONG THE OLDEST
AND MOST CELEBRATED VEHICLES

YOU CAN BUY.

IN 2002, GM HALTED PRODUCTION
OF THE CAMARO,

BUT JUST 7 YEARS LATER, IN 2009,

THE LINE WAS REVIVED

WITH THE FIFTH-GENERATION
CAMARO.

TO COINCIDE WITH THE BRAND'S
50th ANNIVERSARY,

THE SIXTH GENERATION
LAUNCHED IN 2016.

THE CAMARO BODY COMES TOGETHER

AT GM's
STATE-OF-THE-ART FACILITY

IN LANSING GRAND RIVER,
MICHIGAN.

GM HAS BEEN PROUDLY
MANUFACTURING CARS IN MICHIGAN

FOR OVER 100 YEARS.

TECHNICIANS LOAD
A CAMARO PRODUCTION HOOD

ONTO A FIXTURE

SO IT CAN BE INSTALLED NEXT
TO DIMENSIONALLY PERFECT PARTS.

A LASER SCANNING ARM
HELPS AN OPERATOR

CHECK THE HOOD'S DIMENSIONS.

THE SCANNED RESULTS SHOW UP
ON THE SCREEN OF A COMPUTER

THAT CAN INSTANTLY COMPARE
THE PART TO ITS DIGITAL DESIGN.

THE SCANNER ALSO CHECKS THE GAPS
BETWEEN THE PRODUCTION PART

AND THE MODEL PART.

THE DATA GATHERED HERE

FEEDS BACK TO THE APPROPRIATE
SUBASSEMBLY LINES.

TECHNICIANS CAN ADJUST
THE PRODUCTION PROCESS

TO IMPROVE THE RESULTS.

DEPENDING ON WHAT'S NEEDED,

GM USES DIFFERENT TECHNIQUES
TO EXAMINE THE PARAMETERS

OF THE PARTS.

HERE A TECHNICIAN WORKS BY HAND
ON A SMALL, FOCUSED INSPECTION.

HE USES A SET OF CALIPERS

TO MEASURE TINY DIFFERENCES
IN THE GAP SIZES.

AFTER PASSING INSPECTION,

COMPONENTS
GO TO THE BODY ASSEMBLY LINE.

ROBOT ARMS
APPLY ADHESIVE AND SEALER

TO THE PARTIALLY FRAMED BODY.

GM USES MORE THAN 300 FEET
OF ADHESIVE

WHEN BUILDING A CAMARO.

THE ADHESIVE ADDS RIGIDITY
TO THE CAR,

WHICH IMPROVES PERFORMANCE,
HANDLING, AND RIDE QUALITY.

THE BLACK MATERIAL
IS A FORM OF SEALER.

GM STAMPS OUT THE BODY SIZE
FROM A SINGLE PIECE OF STEEL.

THE ROBOTS LOAD
THE BODY SIDES ONTO THE CAR,

HANGING THEM CAREFULLY
ON A SERIES OF SLOTS AND TABS.

NEXT, TWO ROBOTS BRING IN A SET
OF LARGE FIXTURES

DESIGNED TO CLAMP
ALL THE COMPONENTS IN PLACE.

THESE FIXTURES ENSURE THAT
THE STRUCTURE OF THE CAR

IS DIMENSIONALLY CORRECT
BEFORE WELDING BEGINS.

GM USES A COORDINATE MEASURING
MACHINE, OR CMM,

TO AUDIT CRITICAL SUBASSEMBLIES

AND ENSURE THAT THEY
ARE BUILT CORRECTLY.

THE CMM MEASURES ALL DEVIATIONS
FROM THE DESIGN PARAMETERS,

RECORDS THEM,
AND FEEDS THEM INTO A DATABASE.

THIS DATA IS USED
TO DIRECT PROCESS IMPROVEMENTS.

A PRODUCTION TEAM MEMBER
BRINGS A DOOR TO THE CAR.

THE DOOR HINGES HAVE BEEN
PRECISION WELDED TO THE FRAME.

HE HANGS THE DOOR ON THE HINGES,

TORQUES THE BOLTS,
AND RELEASES THE LIFT ASSIST.

AS TEAM MEMBERS
BEGIN THE FRONT END BUILD-UP,

THEY USE A HIGHLY SPECIALIZED
FIXTURE

TO HELP MOUNT THE CAR'S FENDERS.

THE FIXTURE CAN READ ELECTRONIC
TAGS ON THE CARS IN ADVANCE

AND ADJUST ITSELF TO ACCOMMODATE
THE DIFFERENT MODELS

AS THEY COME.

THE ASSEMBLED BODY IN WHITE
TRAVELS TO AN AUDIT BOOTH,

WHERE THE QUALITY OF
ITS SURFACES ARE EVALUATED.

OVER 5,000 SPOT-WELDS
HELP HOLD THE BODY TOGETHER,

BUT ALUMINUM CAN'T BE WELDED
TO STEEL,

SO GM USES RIVETS AND ADHESIVES
TO BOND THE DISSIMILAR METALS.

THIS PROCEDURE ALSO INCREASES
THE CAR'S OVERALL RIGIDITY

BY 20%.

IN THIS STAGE, A SET OF SPRAYERS
SHOWERS THE CAR WITH CLEANER.

THE CAR WILL GO
THROUGH ALTERNATING SPRAY ZONES

AND DIP TANKS.

THEN IT GOES THROUGH AN OVEN

TO COMPLETE
THE PRE-TREATMENT PROCESS.

THE PAINT SHOP GIVES THE CAR
A PRIMER APPLICATION.

THEN A BASE COLOR COAT GOES ON,

FOLLOWED BY A CLEAR COAT
FOR GLOSS AND DURABILITY.

Narrator: THE SIXTH-GENERATION CAMARO
COMES IN THREE DIFFERENT TRIMS.

THE LT MODELS FEATURE GM's
ALL-NEW 3.6-LITER V6 ENGINE,

WHICH IS LIGHTER AND MORE
POWERFUL THAN ITS PREDECESSOR.

TEAM MEMBERS AT GM's
ROMULUS POWERTRAIN FACILITY

IN MICHIGAN BUILD THE V6.

BUILDING AN ENGINE ALWAYS
STARTS WITH THE ENGINE BLOCK.

A TECHNICIAN CAREFULLY LOADS
THE 3.6-LITER ALUMINUM BLOCK

ONTO A FIXTURE
CALLED A PEDESTAL.

ONCE IT'S SECURELY IN PLACE,

SHE SCANS A TWO-DIMENSIONAL
MATRIX TAG.

THIS CREATES AN IDENTIFICATION
NUMBER THAT THE ENGINE

WILL CARRY
THROUGHOUT PRODUCTION.

A TEAM MEMBER LOADS A CRANK
ONTO A FIXTURE,

WHERE A SCANNER READS
THE TWO-DIMENSIONAL MATRIX.

THEN HE PUSHES THE CRANK
INTO AN OILING MECHANISM.

WHEN THE MECHANISM
IS FINISHED OILING,

THE TECHNICIAN REMOVES THE CRANK
AND USES A LIFT ASSIST

TO TRANSFER IT
TO THE ENGINE BLOCK.

THE PISTONS ARE COUNTERBALANCED

FOR ONE SIDE OF THE ENGINE
OR THE OTHER.

HE PUTS A PISTON GUIDE FORK
INSIDE A BORE

AND THEN ALIGNS A CONROD
ON THE OTHER SIDE.

A SEMIAUTOMATIC STUFFER
INSTALLS THE PISTON.

HE REMOVES THE FORK AND
THEN INSTALLS THE CONROD CAP.

AN INITIAL TORQUE
KEEPS THE PISTON IN PLACE.

HE LINES UP THE CRANKSHAFT

FOR INSTALLATION
OF THE NEXT CYLINDER.

AT THE NEXT STATION, THE ENGINE
IS LIFTED OFF ITS PEDESTAL.

CAMERAS CHECK UNDER THE BLOCK
FOR TYPE, ORIENTATION,

AND ERROR PROOFING
OF THE PISTONS.

AUTOMATIC FASTENERS
GIVE THE BOLTS

THEIR FINAL SPECIFIED TORQUE.

A TEAM MEMBER
INSTALLS A COMPONENT

CALLED THE OIL DEFLECTOR PLATE.

SHE LOWERS A MULTI-SPINDLE GUN
INTO POSITION,

THEN TORQUES DOWN
ALL THE BOLTS AT ONCE.

THE TECHNICIAN
ROTATES THE ENGINE

SO SHE CAN EASILY
INSTALL THE OIL PUMP.

SHE STARTS THE BOLTS MANUALLY

TO ENSURE THERE'S
NO RISK OF CROSS-THREADING

WHEN THEY'RE TIGHTENED.

NEXT A TECHNICIAN LOWERS

THE CAMARO'S DUAL OVERHEAD
CAM CYLINDER HEAD

AND CAM CARRIER ONTO
A PREVIOUSLY INSTALLED GASKET,

RETAINED BY DOWEL PINS.

A HIGH-TECH DEVICE
APPLIES A PLASMA TREATMENT

TO THE ENGINE'S FRONT COVER.

THE PLASMA TREATMENT
SIMULTANEOUSLY CLEANS

AND ELECTRICALLY CHARGES
THE SURFACE

IN PREPARATION FOR
A SPECIALIZED SEALANT.

THE RTV,

OR ROOM TEMPERATURE
VULCANIZATION SEALANT,

IS APPLIED TO THE SURFACE

BEFORE A TECHNICIAN
INSTALLS THE COVER.

NEXT, A TEAM MEMBER
INSTALLS THE CAM COVER.

ONCE IT'S IN PLACE,

HE MANUALLY TIGHTENS THE BOLTS.

THE FINAL FASTENING TAKES PLACE
AT THE NEXT STATION.

A MULTI-SPINDLE MECHANISM

TORQUES THE CAM COVER'S
18 BOLTS SIMULTANEOUSLY.

AS WITH EVERY OTHER COMPONENT
ON THE ENGINE,

GM TECHNICIANS
HAVE SCANNED THE CAM COVER

AND ADDED ITS INFORMATION
TO THE ENGINE'S DATA.

BEFORE INSTALLING THE OIL PAN
OVER THE OIL SUCTION PIPE,

GM PLASMA-TREATS
THE CEILING SURFACES

AND APPLIES RTV SEALANT,

THIS PROCESS
HELPS PREVENT LEAKS

OVER THE LIFETIME OF THE ENGINE.

IN THE COLD TEST STATION,

GM CONDUCTS ITS INITIAL TEST
OF THE ENGINE.

SENSORS CLAMP IN PLACE
AND INSTEAD OF FIRING IT UP,

THE TEST STAND SPINS THE ENGINE.

IN JUST OVER A MINUTE,

THE STATION IS ABLE
TO CHECK 1,500 PARAMETERS.

THE CAMARO ENGINE IS COMPLETE.

A TEAM MEMBER
MOVES IT OFF THE LINE.

THANKS TO THE SCANNING PROCESS,

EVERY STEP OF THE PRODUCTION
HAS BEEN RECORDED,

AND THE MANUFACTURING HISTORY
OF EACH COMPONENT

IS COMPLETELY TRACEABLE.

Narrator:
SIXTH-GENERATION CAMAROS

COME WITH SIX-SPEED MANUAL
TRANSMISSIONS

AND ALL-NEW HYDROMATIC
PADDLE SHIFT

EIGHT-SPEED AUTOMATIC
TRANSMISSIONS,

WHICH ARE LIGHTER,
FASTER, AND SMOOTHER

THAN THEIR PREDECESSORS.

GM BUILDS THE CAMARO
TRANSMISSION

AT ITS POWERTRAIN PLANT
IN TOLEDO, OHIO.

A STICKER
ON THE TRANSMISSION CASE

HAS THE TRANSMISSION
UNIT NUMBER, OR TUN,

A SERIAL NUMBER THAT ALL BUILD
DATA WILL BE LINKED TO.

THE TEAM MEMBER
POSITIONS THE EXTENSION GASKET

ON THE CASE.

GM USES THE TWO-DIMENSIONAL
BAR CODE TO RECORD EVERYTHING

THAT HAPPENS
TO THE EXTENSION COMPONENT.

A TEAM MEMBER
INSTALLS THE EXTENSION.

THERE ARE FOUR DIFFERENT CAMERAS
SCANNING

AND ERROR-PROOFING THE ASSEMBLY
AT THIS STATION ALONE,

THE CAMERAS COMPARE
WHAT THEY SEE

TO AN IDEAL IMAGE
OF THE ASSEMBLY.

A TECHNICIAN LOADS A COMPONENT

CALLED THE OUTPUT CARRIER
ONTO A SEMIAUTOMATIC FIXTURE

AND SCANS IT TO RECORD THE STEP.

THE FIXTURE FLIPS THE ASSEMBLY
TO PREPARE IT FOR THE NEXT STEP.

THEN THE TEAM MEMBER
INSTALLS A PART

CALLED THE REACTION CARRIER
AND SCANS IT, AS WELL.

THE ASSEMBLY
AT THIS STATION IS COMPLETE.

THE PART PIVOTS
TO THE NEXT PHASE.

AS THE PART SWINGS AROUND,

IT MEETS THE TRANSMISSION CASE.

A FULLY-AUTOMATED OVERHEAD
GANTRY SYSTEM PICKS UP A BEARING

AND THE CARRIER ASSEMBLY.

IT LOADS THE BEARING
INTO THE BOTTOM

OF THE TRANSMISSION CASE.

IT SLOWLY LOWERS
THE CARRIER ASSEMBLY

ONTO THE BEARING
INSIDE THE CASE.

THE TOOLING ROTATES THE ASSEMBLY

TO PREVENT THE EXTENSION LIP
SEAL FROM ROLLING INSIDE.

A TEAM MEMBER POSITIONS
A TRIPLE CLUTCH HOUSING

ON A PALLET THAT WILL TRAVEL
THROUGH THE ASSEMBLY.

A CNC GANTRY-MOUNTED CAMERA
TAKES HUNDREDS OF PHOTOS

TO MAKE SURE THE PARTS
ARE IN THE RIGHT POSITION.

THE COMPONENTS MUST BE PRECISELY
LOCATED ON THE PALLET

SO THE CNC GANTRY
CAN ASSEMBLE THEM.

AS THE PALLETS MOVE,
THE CNC GANTRY GOES TO WORK,

MEASURING THE PACK TRAVEL

AND SELECTING THE CORRECT
SNAP RINGS TO INSTALL.

A TEAM MEMBER BRINGS
THE COMPLETED TRIPLE CLUTCH

TO THE TRANSMISSION CASE.

THE TECHNICIAN MUST ROTATE
THE CLUTCH AND OUTPUT SHAFT

IN THE OPPOSITE DIRECTIONS

TO SPLINE
EIGHT DIFFERENT FIBER PLATES

WITH TWO DIFFERENT RING GEARS
AS IT DROPS DOWN.

HE SCANS THE CLUTCH TO MARRY
THE PART'S UNIQUE NUMBER

TO THE TRANSMISSION.

WITH SOLENOIDS CALIBRATED
TO THE MILLIAMP,

THE VALVE BODY ASSEMBLY IS
THE TRANSMISSION'S NERVE CENTER.

THOSE SOLENOIDS MUST NOT BE
DAMAGED DURING INSTALLATION.

A SPECIALIZED FIXTURE CLAMPS ON

AND PICKS UP
THE VALVE BODY ASSEMBLY.

IT TRANSFERS THE ASSEMBLY
TO THE TRANSMISSION

AND ALIGNS ITSELF PRECISELY
BEFORE LOWERING INTO PLACE.

THE FIXTURE
RELEASES THE SUBASSEMBLY,

AND THE TRANSMISSION TRAVELS
TO THE NEXT OPERATION.

A TECHNICIAN USES A LIFT ASSIST
TO PICK UP THE TORQUE CONVERTER

AND BRING IT
TO THE TRANSMISSION.

ONCE HE'S LOADED IT IN,

HE USES A SPECIALIZED TOOL
TO ROTATE THE TORQUE CONVERTER

AND DROP IT INTO POSITION.

HE THEN SCANS
THE TWO-DIMENSIONAL CODE.

THE TRANSMISSION IS COMPLETE,

BUT IT MUST GO THROUGH
A QUALITY-CONTROL CHECK

BEFORE SHIPPING OFF.

Narrator: THE CAMARO BODY GOES
STRAIGHT FROM THE PAINT SHOP

TO THE GENERAL ASSEMBLY LINE
AND TRANSFERS

ONTO A CONVEYOR SYSTEM
REFERRED TO AS THE SKILLET.

IT'S TIME
TO ASSEMBLE ALL THE COMPONENTS

INTO A MUSCLE CAR.

OPERATORS USE A SPECIALIZED
LIFT ASSIST FIXTURE

CALLED THE COCKPIT LOADER

TO INSTALL THE DASHBOARD.

THE INJECTION-MOLDED DASHBOARD
INCLUDES THE INSTRUMENT PANEL,

THE AIR-CONDITIONING CONTROLS,
AND THE PASSENGER SIDE AIRBAG.

THEY USE TORQUE CONTROLLED BOLT
DRIVERS TO ATTACH IT IN PLACE.

AS THEY WORK, THE CAR CONTINUES
TO MOVE ON ITS SKILLET.

A WORKER CLEANS A SECTION
OF THE TRUNK SURFACE

BEFORE USING A LOCATING FIXTURE

TO POSITION
THE FAMED CHEVY BOW TIE EMBLEM.

A THREE-RAIL CARRIER SYSTEM

MOVES THE CAR BODY
THROUGH THE NEXT PHASE.

THE POWERTRAIN AND CHASSIS MOVE
ON AN AUTOMATED GUIDED VEHICLE,

OR AGV.

THE AGV
USES A LASER-GUIDED SYSTEM

TO SYNC UP PERFECTLY
WITH THE CARRIER.

THEN IT QUICKLY LIFTS
THE POWERTRAIN AND CHASSIS

UP INTO THE BODY.

TECHNICIANS DRIVE
IN SIX FASTENERS PER SIDE

BEFORE THE AGV LIFT DESCENDS,

SO THEY CAN GET
UNDER THE CHASSIS

AND COMPLETE
THE FASTENING PROCESS.

A WORKER USES A LIFT ASSIST

TO INSTALL THE SEATS
INSIDE THE CAMARO.

A TECHNICIAN LOADS A WHEEL

ONTO A FRONT END
WITH A LIFT ASSIST.

SHE LOOSELY INSTALLS THE LUG
NUTS FOR THE NEXT OPERATION.

AN OPERATOR
USES A PURPOSE-BUILT DEVICE

CALLED THE MULTIPLE LUG NUT
SECURE TOOL

TO TORQUE ALL THE LUG NUTS
SIMULTANEOUSLY.

A TECHNICIAN CONNECTS
THE HORN AND THE AIRBAG.

WORKERS ADD ALL THE FLUIDS,

INCLUDING COOLANT,
FUEL, RADIATOR,

BRAKE, AND WASHER FLUID.

THE CAR'S DOORS ARE REMOVED
BEFORE GENERAL ASSEMBLY BEGINS.

THEY TRAVEL ON A SEPARATE
SUBASSEMBLY LINE.

THEY SYNC BACK UP
WITH THE CAR HERE,

WHERE A WORKER INSTALLS THEM.

THE THREE-RAIL CARRIER
RELEASES THE CAR,

AND A SUPPORTING TRANSFER
FIXTURE

LOWERS IT DOWN
ONTO A FINAL LINE CONVEYOR.

THE CAMARO CROSSES
A RUMBLE STRIP

AS IT TAKES ITS FIRST DRIVE.

THE CAR THEN PARKS
AT THE WHEEL ALIGNMENT STATION.

IN THE PIT UNDERNEATH,

A TECHNICIAN
VALIDATES THE WHEELS' PRESETS

AND MAKES FINAL ADJUSTMENTS,

FINE-TUNING THE WHEEL ALIGNMENT
AND CAMBER.

THE CAMARO COMES WITH THREE
DIFFERENT-SIZED WHEEL PACKAGES,

SO THESE ADJUSTMENTS
CAN VARY SLIGHTLY,

DEPENDING ON WHAT
THE CUSTOMER ORDERED.

AT THE NEXT STATION, THE DRIVER

PULLS ONTO A SET OF ROLLERS
FOR THE DYNAMIC VEHICLE TEST.

HE RUNS THE CAR THROUGH A GAMUT
OF DIFFERENT DRIVING MODES,

AS THE STATION'S EQUIPMENT TESTS
EVERY PARAMETER,

FROM THE RPMs TO THE GEAR
SHIFTING AND BRAKING.

THOROUGH AS THE TESTS ARE,

THE WHOLE PROCESS
TAKES LESS THAN 2 MINUTES.

THEN THE CAR IS OFF.

AT THE FINAL STEP,
A CONVEYOR SYSTEM

MOVES THE CARS PAST A BANK
OF FULL-SPECTRUM LIGHTS.

TRAINED TECHNICIANS EXAMINE
EVERY ASPECT OF THE VEHICLE,

BOTH INSIDE AND OUT,

ASSESSING ALL SURFACES
FOR FIT AND FINISH.

THE PROCESS IS KNOWN
AS THE C.A.R.E. LINE, AN ACRONYM

FOR CUSTOMER ACCEPTANCE REVIEW
AND EVALUATION.

AFTER A CAR MEETS
FINAL CARE INSPECTION CRITERIA,

IT'S FINALLY READY
TO HEAD OUT INTO THE WORLD.

THE SIXTH-GENERATION CAMARO

RECALLS THE GLORY DAYS
OF 1960s MUSCLE CARS.

IN FACT, IT BEARS A RESEMBLANCE
TO THE ORIGINAL 1967 CAMARO

ITSELF.

BUT LIFT THE HOOD,

AND IT'S IMMEDIATELY CLEAR

THIS IS A 21st-CENTURY
HIGH-PERFORMANCE VEHICLE.

THE INTERIOR COCKPIT
LEAVES NO DOUBT

THAT THIS IS A VERY CONTEMPORARY
TAKE ON A CLASSIC.

FROM BACK ROADS AND HIGHWAYS
TO BIG-BUDGET MOVIES,

FEW CARS IN AMERICAN
AUTOMOTIVE HISTORY HAVE EMBEDDED

THEMSELVES SO THOROUGHLY
IN THE COLLECTIVE MEMORY.

THE CHEVY CAMARO
IS ON EVERYBODY'S LIST

OF THE TOP 10 MUSCLE CARS
OF ALL TIME.

THANKS
TO STATE-OF-THE-ART TECHNOLOGY

AND CLEVER ENGINEERING,

THE MODERN INCARNATION
OF THIS LEGEND

IS LIGHTER AND MORE MUSCULAR
THAN EVER BEFORE.