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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"
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THE PORSCHE PANAMERA...
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00:00:04,370 --> 00:00:08,207
A GRAND TOURER THAT DRIVES
LIKE A HIGH-END SPORTS CAR.
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00:00:08,240 --> 00:00:11,210
-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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AT THE PORSCHE MUSEUM
IN STUTTGART, GERMANY,
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THE COMPANY'S FAMOUS
CAR DESIGNS ARE ON DISPLAY.
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IT THE LATE 1940s, THE 356
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WAS THE FIRST OFFICIAL SERIAL
PRODUCTION CAR MADE BY PORSCHE.
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00:00:37,136 --> 00:00:41,373
NEARBY IS A 1975 VERSION
OF THE 911.
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00:00:41,406 --> 00:00:44,642
THE MOBY DICK IS A 1978 RACECAR
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DESIGNED
TO COMPETE IN U.S. EVENTS.
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00:00:49,448 --> 00:00:51,750
WITH MORE THAN 28,000 VICTORIES,
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00:00:51,783 --> 00:00:55,754
PORSCHE IS ONE OF THE MOST
SUCCESSFUL NAMES IN MOTORSPORT.
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BUT RACECARS AREN'T KNOWN
FOR BEING COMFORTABLE,
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SO PORSCHE CREATED
A FOUR-DOOR LUXURY SEDAN
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THAT COMBINED POWER AND SPEED
WITH COMFORT AND STYLE.
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IN FACT,
THE PANAMERA'S PERFORMANCE
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RIVALS THAT OF ITS CELEBRATED
COUNTERPART, THE 911.
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00:01:19,045 --> 00:01:22,715
THE PANAMERA FEATURES
A LIGHTWEIGHT BODY SHELL.
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00:01:22,748 --> 00:01:27,920
MANUFACTURING IT BEGINS
WITH HUGE PRESSING TOOLS.
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00:01:27,953 --> 00:01:33,259
THE PRESS MANUFACTURES THE CAR'S
BODY SIDES IN SIX STEPS.
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00:01:39,230 --> 00:01:40,765
IN A CONTROL STATION,
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AN OPERATOR
MONITORS AND MANAGES PRODUCTION.
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00:01:44,637 --> 00:01:47,939
A MECHANISM USES SUCTION
TO PICK UP A SHEET OF METAL
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00:01:47,974 --> 00:01:50,576
AND TRANSFER IT
TO THE PRESSING TOOL.
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PRESSING TOOLS HAVE ALREADY
STAMPED OUT THE INITIAL SHAPE
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00:01:57,281 --> 00:01:59,317
AND OPENINGS ON THESE SHEETS.
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00:01:59,352 --> 00:02:02,421
THE NEXT TOOL
SHAPES THE METAL INTO A PANEL.
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00:02:02,454 --> 00:02:06,459
THIS PANEL INCLUDES A PORTION
OF THE ROOF, THE DOOR OPENINGS,
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00:02:06,492 --> 00:02:10,530
AND THE REAR FENDER WITH
AN OPENING FOR THE FUEL CAP.
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00:02:13,098 --> 00:02:17,003
TRANSFER MECHANISMS
USE VACUUM-POWERED SUCTION CUPS
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00:02:17,036 --> 00:02:20,105
TO QUICKLY MOVE THE PANEL
FROM ONE STATION TO ANOTHER.
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00:02:20,139 --> 00:02:22,442
PRESSING TOOLS
COMPLETE ITS FORMATION
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IN A HIGHLY EFFICIENT, FULLY
AUTOMATED STAMPING PROCESS.
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THE FINISHED PANELS
EXIT THE PRESS
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AND ENTER
A QUALITY-CONTROL AREA.
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TRAINED INSPECTORS
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EXAMINE THEIR SURFACES
VISUALLY AND MANUALLY.
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00:02:44,997 --> 00:02:47,232
PORSCHE BUILDS THE LIGHTWEIGHT
BODY SHELL
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USING A VARIETY OF METALS,
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INCLUDING HIGH-STRENGTH STEELS,
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00:02:50,868 --> 00:02:54,473
STAINLESS STEEL, MAGNESIUM,
AND ALUMINUM.
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00:02:54,507 --> 00:02:57,576
THIS RESULTS
IN A LOW OVERALL WEIGHT.
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IT ALSO PRODUCES A SAFE,
RESILIENT VEHICLE.
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ROBOTS SIMULTANEOUSLY BRING
THE LEFT AND RIGHT BODY SIDES
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00:03:05,516 --> 00:03:08,920
TO THE FLOOR PLATE AND INNER
PANEL OF THE FRAMEWORK.
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00:03:08,955 --> 00:03:13,725
THIS STEP COMPLETES
THE DOOR-OPENING STRUCTURES.
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00:03:17,295 --> 00:03:20,733
ROBOTS USE SPECIALIZED FIXTURES
TO ALIGN, MOUNT,
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00:03:20,766 --> 00:03:24,669
AND ATTACH THE PANAMERA'S
LIGHTWEIGHT ALUMINUM REAR DOORS.
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00:03:24,703 --> 00:03:27,338
THE DOORS COME WITH INTEGRATED
SIDE-IMPACT PROTECTION
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IN ALL MODELS.
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NEXT, ROBOTS TRANSFER
THE FRONT DOORS
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TO THE BODY SHELL
AND INSTALL THEM.
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THE INSTALLATION FIXTURES
INCLUDE CAMERAS
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THAT ENSURE CORRECT ALIGNMENT
OF THE DOORS
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WITH THEIR OPENINGS.
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00:03:44,689 --> 00:03:47,592
CUSTOMERS CAN OPT
FOR A SOFT-CLOSE SYSTEM,
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WHICH USES
A SMALL ELECTRIC MOTOR
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TO SHUT THE DOORS
GENTLY BUT FIRMLY
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REGARDLESS OF HOW MUCH
OR HOW LITTLE FORCE IS USED.
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00:03:59,538 --> 00:04:03,375
AS THE CAR BODY ADVANCES
ALONG THE PRODUCTION LINE,
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00:04:03,408 --> 00:04:07,045
WORKERS MOUNT FIXTURES
ON THE BODY SHELL.
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00:04:07,080 --> 00:04:10,216
THE PANAMERA IS EQUIPPED
WITH AN ACTIVE HOOD SYSTEM
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DESIGNED TO HELP
IMPROVE PEDESTRIAN SAFETY.
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IF THE CAR'S FRONT SENSORS
DETECT A COLLISION, THE SYSTEM
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00:04:16,788 --> 00:04:20,826
INSTANTLY RAISES THE REAR
OF THE HOOD TO REDUCE INJURY.
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00:04:41,579 --> 00:04:45,151
THEY PAINT THE ASSEMBLED BODY
IN FIVE STAGES.
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00:04:55,661 --> 00:04:58,697
FIRST, THE CAR BODY
IS COATED WITH A PHOSPHATE
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00:04:58,730 --> 00:05:01,901
FOR IMPROVED ADHESION.
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00:05:01,934 --> 00:05:04,971
THEY ALSO USE
AN ELECTROPHORETIC COATING,
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SEAM SEALING,
AND FILLER COATING.
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00:05:07,105 --> 00:05:10,308
DURING THE FINAL STEP,
ROBOTS COAT THE METAL SHELL
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00:05:10,341 --> 00:05:12,745
WITH ITS COLORED BASE COAT
AND CLEAR COAT.
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00:05:12,778 --> 00:05:17,049
THEN THE SHELL IS SENT THROUGH
AN ENORMOUS DRYING OVEN.
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00:05:17,081 --> 00:05:19,050
AFTER THE TOP COAT DRIES,
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THE BODY ARRIVES AT A SPECIALLY
DESIGNED LIGHT TUNNEL.
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00:05:22,387 --> 00:05:25,324
THE LIGHT TUNNEL IS EQUIPPED
WITH L.E.D. TUBES
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POSITIONED TO CREATE
A UNIFORM LIGHT STRIP PATTERN
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00:05:27,793 --> 00:05:30,062
ON THE SURFACE OF THE CAR BODY.
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00:05:30,095 --> 00:05:33,432
THIS MAKES IT EASIER FOR A TEAM
OF QUALITY-CONTROL INSPECTORS
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TO DETECT THE TINIEST FLAWS
IN THE PAINT JOB.
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00:05:40,706 --> 00:05:43,842
IF THEY FIND
EVEN THE SLIGHTEST IMPERFECTION,
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00:05:43,875 --> 00:05:46,578
THE INSPECTORS REMOVE THE BODY
FROM THE LINE
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00:05:46,612 --> 00:05:50,349
AND SEND IT FOR SPOT REPAIR.
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THE INSPECTORS ARE SATISFIED
WITH THE PAINT JOB,
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00:05:53,384 --> 00:05:57,322
SO THE CAR BODY IS READY TO HEAD
TO THE ASSEMBLY LINE.
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Narrator:
THE PORSCHE PANAMERA
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COMES IN MANY DIFFERENT
POWER TRAIN CONFIGURATIONS,
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00:06:14,703 --> 00:06:17,606
WITH THE PANAMERA S FEATURING
A BURLY 3-LITER,
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00:06:17,640 --> 00:06:20,243
TWIN TURBOCHARGED V-6.
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00:06:22,412 --> 00:06:24,513
A TECHNICIAN PLACES
CONNECTING RODS
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00:06:24,548 --> 00:06:29,351
IN A MACHINE TO CLEAN OFF
ANY STRAY PARTICLES.
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00:06:29,385 --> 00:06:33,122
HE SCANS THE CONRODS, CONFIRMING
THEY'RE THE RIGHT COMPONENTS
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00:06:33,154 --> 00:06:36,025
FOR THE ENGINE HE'S BUILDING.
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00:06:36,058 --> 00:06:40,130
NEXT HE UNSCREWS THE CAPS
AND INSTALLS THE BEARINGS.
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00:06:40,162 --> 00:06:44,066
THE OUTSIDE SURFACE OF EACH
BEARING HAS A TINY NOSE ON IT.
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00:06:44,099 --> 00:06:47,770
THIS FITS PRECISELY INTO A SMALL
NOTCH IN THE CONNECTING ROD,
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00:06:47,803 --> 00:06:50,073
ENSURING THE TECHNICIAN
INSTALLS THE RIGHT BEARING
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00:06:50,106 --> 00:06:52,174
IN THE RIGHT CONROD.
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00:06:53,876 --> 00:06:57,246
HE ASSEMBLES THE CONROD
TO THE PISTONHEAD
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00:06:57,279 --> 00:06:59,282
WITH A PURPOSE-BUILT MACHINE.
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00:06:59,315 --> 00:07:01,517
THE MACHINE
SCANS THE CONNECTING ROD
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00:07:01,551 --> 00:07:05,622
FROM ABOVE TO VERIFY ONCE AGAIN
THAT IT'S THE RIGHT PART.
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00:07:08,825 --> 00:07:10,392
HE PLACES THE PISTONHEAD
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00:07:10,426 --> 00:07:14,598
IN A VISE DESIGNED
TO COMPRESS THE RINGS.
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00:07:14,630 --> 00:07:16,599
A LIFT ASSIST
HELPS THE TECHNICIAN
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00:07:16,633 --> 00:07:18,601
BRING THE CRANKSHAFT
TO THE ENGINE BLOCK
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00:07:18,635 --> 00:07:20,871
AND LOWER IT IN PLACE.
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00:07:23,873 --> 00:07:26,909
HE ROTATES THE BLOCK
ON ITS ASSEMBLY FIXTURE
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00:07:26,943 --> 00:07:30,147
TO GAIN ACCESS TO THE PISTON
BORE HOLES.
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HE CAREFULLY INSTALLS
SIX PISTONS IN THEIR BORES
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ONE BY ONE.
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ONCE THEY'RE IN PLACE,
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HE TURNS THE BLOCK AGAIN
TO INSTALL THE CONROD CAPS
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00:07:46,596 --> 00:07:49,733
USING A TORQUING DEVICE
TO TIGHTEN THEM.
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00:07:51,902 --> 00:07:54,402
HE MANUALLY ROTATES
THE CRANKSHAFT TO MAKE SURE
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00:07:54,436 --> 00:07:57,739
THE PISTONS MOVE SMOOTHLY.
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00:07:57,772 --> 00:07:59,876
A FULLY AUTOMATED STATION BRINGS
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00:07:59,909 --> 00:08:02,611
THE UPPER AND LOWER SECTIONS
OF THE ENGINE BLOCK TOGETHER
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00:08:02,645 --> 00:08:05,080
AND BOLTS THEM SECURELY.
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00:08:05,114 --> 00:08:08,517
THE BOLTING PROCESS
IS PERFECTLY SYNCHRONIZED
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00:08:08,551 --> 00:08:11,553
TO MAKE THE BEST CONNECTION
POSSIBLE.
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00:08:11,587 --> 00:08:13,556
PORSCHE HAS DESIGNED
FAIL-SAFE FEATURES
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00:08:13,589 --> 00:08:18,995
INTO THE MANUFACTURING PROCESS
TO PREVENT ASSEMBLY ERRORS.
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00:08:19,027 --> 00:08:20,830
GUIDE PINS ON A LIFT ASSIST
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00:08:20,864 --> 00:08:23,900
HELP THE OPERATOR
POSITION THE CYLINDER HEAD.
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00:08:25,734 --> 00:08:28,136
A TECHNICIAN DROPS
THE CYLINDER HEAD BOLTS
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00:08:28,171 --> 00:08:30,839
INTO THEIR POSITIONS
BEFORE TORQUING THEM DOWN
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00:08:30,873 --> 00:08:32,943
ONE BY ONE.
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00:08:35,378 --> 00:08:38,147
HE GREASES THE CYLINDER HEADS
TO PREPARE THEM
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00:08:38,180 --> 00:08:41,517
FOR THE CAMSHAFT INSTALLATION.
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00:08:41,551 --> 00:08:44,186
THE TECHNICIAN CAREFULLY PLACES
THE CAMSHAFTS
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00:08:44,219 --> 00:08:45,754
OVER THE CYLINDER HEADS.
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00:08:45,787 --> 00:08:49,459
HE LOCKS IT IN PLACE
WITH A JIG, THEN BOLTS IT DOWN.
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00:08:53,229 --> 00:08:56,532
A WORKER POSITIONS
THE PANAMERA'S TIMING CHAIN,
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00:08:56,565 --> 00:09:01,405
CAREFULLY THREADING IT
ONTO THE CAMSHAFT ADJUSTERS.
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00:09:01,437 --> 00:09:05,207
THE CHAINS OPTIMIZE THE TIMING
FOR DIFFERENT LOADS,
139
00:09:05,242 --> 00:09:07,443
ENSURING THE ROTATION
OF THE CRANKSHAFT
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00:09:07,475 --> 00:09:11,181
AND THE CAMSHAFT
ARE PERFECTLY SYNCHRONIZED.
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00:09:16,485 --> 00:09:19,155
THE TIMING CASE IS MADE
OF MAGNESIUM,
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00:09:19,189 --> 00:09:21,791
WHICH IS 33% LIGHTER
THAN ALUMINUM
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00:09:21,824 --> 00:09:25,695
AND 75% LIGHTER THAN STEEL.
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00:09:25,728 --> 00:09:27,796
A TECHNICIAN
FINISHES THE OPERATION
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00:09:27,830 --> 00:09:32,102
BY INSTALLING THE CYLINDER
HEAD COVER AND IGNITION COILS.
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00:09:36,171 --> 00:09:38,974
THE V-6 ENGINE
OF THE PORSCHE PANAMERA S
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00:09:39,008 --> 00:09:41,978
IS NEARLY DONE.
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00:09:42,012 --> 00:09:45,647
A WORKER CAREFULLY PLACES
THE COMPOSITE INTAKE MANIFOLD
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00:09:45,681 --> 00:09:47,082
INTO POSITION.
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00:09:47,115 --> 00:09:49,718
HE USES A TORQUE-CONTROLLED
BOLTING DEVICE
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00:09:49,752 --> 00:09:53,924
TO RUN DOWN THE SCREWS
AND BOLT IT SECURELY IN PLACE.
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00:09:57,759 --> 00:10:01,196
THE COMPLETED V-6
CAN TAKE THE PANAMERA S
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00:10:01,229 --> 00:10:04,432
FROM ZERO TO 60
IN JUST 5.1 SECONDS,
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00:10:04,466 --> 00:10:08,838
WITH A TOP SPEED
OF ALMOST 180 MILES PER HOUR.
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00:10:14,008 --> 00:10:16,812
THE ENGINE JOINS THE REST
OF THE POWER TRAIN
156
00:10:16,845 --> 00:10:19,782
ON A YELLOW SUBASSEMBLY WAGON.
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00:10:19,815 --> 00:10:21,550
AS THE WAGON MOVES ON ITS TRACK,
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00:10:21,584 --> 00:10:23,787
MEMBERS
OF THE PORSCHE PRODUCTION TEAM
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00:10:23,820 --> 00:10:25,754
COMPLETE THE ASSEMBLY.
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00:10:27,923 --> 00:10:30,392
A TECHNICIAN
USES A TORQUE-CONTROLLED DRIVER
161
00:10:30,426 --> 00:10:31,628
TO RUN DOWN THE BOLTS
162
00:10:31,661 --> 00:10:35,064
THAT ATTACH THE PROP SHAFT
TO THE TRANSMISSION.
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00:10:35,096 --> 00:10:39,535
THE SHAFT CAN NOW TRANSFER POWER
TO THE REAR AXLE.
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00:10:39,569 --> 00:10:41,371
MADE OF STAINLESS STEEL,
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00:10:41,403 --> 00:10:43,639
THE EXHAUST
IS A LIGHTWEIGHT SYSTEM,
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00:10:43,672 --> 00:10:46,676
FEATURING CATALYTIC CONVERTERS
THAT HEAT UP RAPIDLY
167
00:10:46,709 --> 00:10:48,979
FOR INCREASED EMISSIONS CONTROL.
168
00:10:49,012 --> 00:10:53,748
INTERNAL DESIGN FEATURES
ENHANCE SOUND AT HIGH REVS.
169
00:10:53,782 --> 00:10:55,685
VARIABLE CAMSHAFT CONTROL,
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00:10:55,718 --> 00:10:58,454
TURBO CHARGING, RECUPERATION,
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00:10:58,488 --> 00:11:00,022
AUTO START-STOP,
172
00:11:00,056 --> 00:11:01,791
AND A COASTING FUNCTION
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00:11:01,825 --> 00:11:04,627
ALL COMBINE
TO MAKE THIS V-6 MORE EFFICIENT
174
00:11:04,661 --> 00:11:07,364
AND MORE POWERFUL
THAN ITS PREDECESSOR.
175
00:11:15,000 --> 00:11:16,969
Narrator:
THE PANAMERA'S PERFORMANCE
176
00:11:17,001 --> 00:11:19,771
RECALLS THE SPORTS CAR POWER
AND AGILITY
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00:11:19,804 --> 00:11:21,674
THAT MADE PORSCHE FAMOUS,
178
00:11:21,707 --> 00:11:26,011
BUT THE INTERIOR IS THAT
OF A PLUSH AND ROOMY SEDAN.
179
00:11:27,545 --> 00:11:30,547
BUYERS CAN CUSTOMIZE EVERYTHING
FROM THE DASHBOARD
180
00:11:30,582 --> 00:11:32,617
TO THE SEAT COVERS.
181
00:11:35,186 --> 00:11:37,689
PANAMERA CAR BODIES
TAKE THE TRAIN
182
00:11:37,723 --> 00:11:39,623
FROM THE PORSCHE FACILITY
IN HANOVER
183
00:11:39,656 --> 00:11:41,892
TO THIS PLANT IN LEIPZIG.
184
00:11:41,926 --> 00:11:47,165
FIRST, THEY ORGANIZE THE CARS
IN AN OPTIMAL SEQUENCE.
185
00:11:47,199 --> 00:11:52,203
THEN THE CAR BODIES DESCEND
TO THE MAIN ASSEMBLY AREA.
186
00:11:52,237 --> 00:11:54,171
WITH THE HELP OF A LIFT ASSIST,
187
00:11:54,204 --> 00:11:58,075
IT TAKES JUST 2 1/2 MINUTES
TO INSTALL THE DASHBOARD.
188
00:11:58,108 --> 00:12:00,545
SINCE EACH PANAMERA
IS CUSTOM-MADE,
189
00:12:00,578 --> 00:12:03,115
EACH DASHBOARD IS UNIQUE.
190
00:12:06,184 --> 00:12:09,286
BUILT BY A NEARBY SUPPLIER,
191
00:12:09,319 --> 00:12:13,824
THE DASHBOARDS COME
WITH THE WIRING HARNESS.
192
00:12:13,857 --> 00:12:16,328
THE HARNESS IS UNIQUE
TO THE CAR, TOO.
193
00:12:16,362 --> 00:12:17,962
THE NUMBER OF CONNECTIONS
DEPENDS
194
00:12:17,996 --> 00:12:21,567
ON THE CUSTOMER'S
SPECIFIC REQUIREMENTS.
195
00:12:21,599 --> 00:12:24,735
WHEN THE COMPUTER PROGRAM
RESPONSIBLE FOR SEQUENCING
196
00:12:24,770 --> 00:12:27,271
THE CARS CALCULATES THE ORDER
OF PRODUCTION,
197
00:12:27,304 --> 00:12:32,176
IT FACTORS IN THE AVAILABILITY
OF THE PARTS REQUIRED.
198
00:12:32,210 --> 00:12:34,712
IT ALSO CONSIDERS
THE ASSEMBLY TEAM'S NEED
199
00:12:34,746 --> 00:12:36,781
FOR VARIETY.
200
00:12:36,814 --> 00:12:39,751
THE TEAM CONSISTS
OF HIGHLY TRAINED TECHNICIANS,
201
00:12:39,785 --> 00:12:42,386
CAPABLE OF PERFORMING
MULTIPLE TASKS.
202
00:12:42,420 --> 00:12:45,056
PROGRAMMING VARIETY
INTO THE PRODUCTION LINE
203
00:12:45,089 --> 00:12:47,759
PROMOTES
HIGH-QUALITY WORKMANSHIP.
204
00:12:53,665 --> 00:12:56,735
A ROBOT USES
VACUUM-POWERED SUCTION CUPS
205
00:12:56,767 --> 00:12:58,771
TO HOLD A WINDSHIELD IN PLACE
206
00:12:58,804 --> 00:13:02,540
AS A BEAD OF SEALANT
IS APPLIED AROUND THE PERIMETER.
207
00:13:05,043 --> 00:13:09,147
CUSTOMERS CAN OPT FOR THERMALLY
AND NOISE-INSULATED GLASS,
208
00:13:09,180 --> 00:13:12,483
AS WELL AS DARK TINTING
TO ENHANCE PRIVACY.
209
00:13:15,185 --> 00:13:19,290
THE ROBOT CAREFULLY POSITIONS
THE GLASS ON A TABLE,
210
00:13:19,324 --> 00:13:23,594
ENSURING THAT IT'S IN PRECISELY
THE RIGHT SPOT FOR INSTALLATION.
211
00:13:28,032 --> 00:13:29,867
WITH THE SEALANT APPLIED
212
00:13:29,901 --> 00:13:32,737
AND THE WINDSHIELD PERFECTLY
CENTERED ON ITS FIXTURE,
213
00:13:32,771 --> 00:13:36,574
THE ROBOT CAN QUICKLY
INSTALL THE GLASS IN ITS FRAME.
214
00:13:39,242 --> 00:13:41,011
A PORSCHE ASSEMBLY TEAM MEMBER
215
00:13:41,045 --> 00:13:44,015
BRINGS THE REAR CENTER
CONSOLE COVER INTO THE CAR
216
00:13:44,048 --> 00:13:48,186
AND USES A DRIVER TO INSTALL IT.
217
00:13:48,218 --> 00:13:53,124
INSTALLATION OF THE CONSOLES
CAN TAKE UP TO 9 MINUTES.
218
00:13:53,157 --> 00:13:57,728
THIS OF COURSE DEPENDS ON THE
OPTIONS CHOSEN BY THE CUSTOMER.
219
00:13:57,761 --> 00:14:01,933
HERE, THE TECHNICIAN INSTALLS
THE CONSOLE'S FRONT SECTION.
220
00:14:01,967 --> 00:14:05,270
IT INCLUDES THE CONTROL PANEL
FOR THE AIR CONDITIONER
221
00:14:05,304 --> 00:14:07,572
AND THE COVER
OF THE GEAR SHIFT MODULE,
222
00:14:07,604 --> 00:14:09,273
WHICH HOUSES MULTIPLE CONTROLS
223
00:14:09,306 --> 00:14:12,677
ON EITHER SIDE
OF THE STICK SHIFTER.
224
00:14:21,852 --> 00:14:25,122
HERE, TECHNICIANS
INSTALL THE FRONT SEATS.
225
00:14:25,155 --> 00:14:28,727
PORSCHE PRACTICES
MODEL-MIXED PRODUCTION.
226
00:14:28,760 --> 00:14:31,196
THIS MEANS CARS
WITH A HIGH NUMBER OF OPTIONS
227
00:14:31,229 --> 00:14:36,000
ARE INTERSPERSED
WITH LOW-OPTION VERSIONS.
228
00:14:36,034 --> 00:14:39,136
MIXED PRODUCTION
HELPS KEEP PRODUCTION TIME
229
00:14:39,170 --> 00:14:40,671
AT A CONSTANT RATE,
230
00:14:40,704 --> 00:14:45,143
REGARDLESS OF THE COMPLEXITY
OF A PARTICULAR ASSEMBLY.
231
00:14:46,544 --> 00:14:49,481
TEAM MEMBERS
INSTALL THE FRONT-END MODULE.
232
00:14:49,515 --> 00:14:53,851
THIS MODULE CONTAINS THE CAR'S
COMPLETE COOLING PACKAGE.
233
00:14:53,885 --> 00:14:56,388
THEY FASTEN IT IN TWO STAGES...
234
00:14:56,420 --> 00:14:58,555
FIRST
WITH BATTERY-POWERED DRIVERS
235
00:14:58,589 --> 00:15:01,759
AND THEN WITH
A TORQUE-CONTROLLED TIGHTENER.
236
00:15:04,094 --> 00:15:06,630
NEXT,
THEY ADD THE LIGHTWEIGHT BUMPER,
237
00:15:06,664 --> 00:15:09,800
WHICH HELPS TO DEFINE
THE SIGNATURE SLEEK PORSCHE LOOK
238
00:15:09,834 --> 00:15:13,137
WITH ITS SLOPING NOSE
AND LONG-SLUNG GRILLE.
239
00:15:15,073 --> 00:15:17,042
A TECHNICIAN
FITS THE HEADLIGHTS
240
00:15:17,074 --> 00:15:19,076
SNUGLY INTO THEIR APERTURES.
241
00:15:19,109 --> 00:15:21,779
THEY'RE SHAPED LIKE
UPSIDE-DOWN TEARDROPS.
242
00:15:21,813 --> 00:15:25,551
SPECIALISTS WILL LATER TUNE
THEIR HEIGHT AND DIRECTION.
243
00:15:27,019 --> 00:15:28,553
A WORKER USES A TOOL
244
00:15:28,585 --> 00:15:31,188
TO CHECK THE GAPS
BETWEEN THE HOOD, THE BUMPER,
245
00:15:31,223 --> 00:15:33,857
AND THE FENDERS.
246
00:15:33,891 --> 00:15:38,530
THE CARS MOVE ON PLATFORMS
EQUIPPED WITH WOOD FLOORING.
247
00:15:38,563 --> 00:15:41,533
WOOD FLOORING IS MORE
ERGONOMICALLY COMFORTABLE
248
00:15:41,565 --> 00:15:43,000
FOR THE ASSEMBLY TEAM MEMBERS
249
00:15:43,034 --> 00:15:46,136
TO WORK ON
THAN CONCRETE OR STEEL.
250
00:15:46,170 --> 00:15:48,039
FOR ADDITIONAL
ERGONOMIC COMFORT,
251
00:15:48,072 --> 00:15:51,944
A TECHNICIAN USES A LIFT
ASSIST TO INSTALL A DOOR.
252
00:15:53,910 --> 00:15:55,545
THE UNDERSIDE OF THE CAR BODY
253
00:15:55,579 --> 00:15:58,215
HAS BEEN LEFT
OPEN TO ALLOW FOR ITS MARRIAGE
254
00:15:58,248 --> 00:15:59,984
WITH THE POWER TRAIN.
255
00:16:00,017 --> 00:16:03,720
THE POWER TRAIN SLIDES LATERALLY
INTO POSITION ON ITS FIXTURE
256
00:16:03,755 --> 00:16:08,460
AS AN OVERHEAD CARRIER
BRINGS THE BODY OVER IT.
257
00:16:08,492 --> 00:16:10,828
THEN THE POWER TRAIN ASCENDS.
258
00:16:10,862 --> 00:16:14,165
AT THIS FACILITY, THE MARRIAGE
IS ENTIRELY AUTOMATED
259
00:16:14,199 --> 00:16:16,868
AND TAKES JUST 2 MINUTES
TO COMPLETE.
260
00:16:23,507 --> 00:16:26,944
A TECHNICIAN INSTALLS
THE DRIVER-SIDE FRONT AIR BAG
261
00:16:26,977 --> 00:16:28,979
IN THE STEERING WHEEL.
262
00:16:29,014 --> 00:16:30,415
FOR MINOR ACCIDENTS,
263
00:16:30,449 --> 00:16:34,151
THE AIR BAGS PARTIALLY INFLATE
TO MINIMIZE DISCOMFORT.
264
00:16:38,823 --> 00:16:42,126
A TEAM MEMBER WORKS
WITH A FULLY AUTOMATED MECHANISM
265
00:16:42,160 --> 00:16:46,930
TO BRING A WHEEL
TO THE RIGHT REAR WHEELBASE,
266
00:16:46,963 --> 00:16:50,834
MOUNT IT, AND TORQUE THE LUGS.
267
00:16:50,867 --> 00:16:55,172
THE PANAMERA COMES STANDARD
WITH 18-INCH ALLOY WHEELS
268
00:16:55,205 --> 00:16:58,375
AND THE PORSCHE ACTIVE
SUSPENSION MANAGEMENT SYSTEM,
269
00:16:58,410 --> 00:17:00,211
WHICH ADJUSTS THE DAMPING FORCE
270
00:17:00,245 --> 00:17:03,949
ON EACH WHEEL
ACCORDING TO ROAD CONDITIONS.
271
00:17:09,500 --> 00:17:12,402
Narrator: IT'S HARD TO BELIEVE
THAT PORSCHE WAS NEARLY BANKRUPT
272
00:17:12,435 --> 00:17:14,170
IN THE EARLY 1990s.
273
00:17:14,204 --> 00:17:17,574
THE COMPANY TURNED ITSELF AROUND
SO COMPLETELY THAT IT NOW
274
00:17:17,607 --> 00:17:21,278
MAKES MORE MONEY PER CAR
THAN ANY OTHER MANUFACTURER.
275
00:17:21,311 --> 00:17:22,846
THE TURNAROUND BEGAN
WHEN PORSCHE
276
00:17:22,878 --> 00:17:26,516
INTRODUCED LEAN MANUFACTURING
PRINCIPLES FROM JAPAN.
277
00:17:28,551 --> 00:17:32,588
FAMED LEAN MANUFACTURING
CONSULTANT W. EDWARDS DEMING
278
00:17:32,622 --> 00:17:37,461
WROTE, "YOU CAN'T INSPECT
QUALITY INTO A PRODUCT."
279
00:17:37,493 --> 00:17:41,363
IN OTHER WORDS, THE QUALITY
IS EITHER THERE, OR IT'S NOT.
280
00:17:41,397 --> 00:17:45,367
NEVERTHELESS, QUALITY CONTROL
IS A CRUCIALLY IMPORTANT STEP
281
00:17:45,402 --> 00:17:46,703
IN PRODUCTION.
282
00:17:46,736 --> 00:17:48,571
A HIGHLY TRAINED INSPECTOR
283
00:17:48,606 --> 00:17:52,375
SCRUTINIZES EVERY ASPECT
OF THE CAR INSIDE AND OUT,
284
00:17:52,408 --> 00:17:56,213
NOTING AND RECORDING ANY FLAWS.
285
00:17:56,245 --> 00:17:59,715
BEFORE STARTING, INSPECTORS
MUST REMOVE ANY BELTS,
286
00:17:59,750 --> 00:18:03,921
WATCHES, OR OTHER METAL
THAT COULD SCRATCH THE PAINT.
287
00:18:03,953 --> 00:18:06,722
WITH THE FIT
AND FINISH FULLY INSPECTED,
288
00:18:06,755 --> 00:18:11,060
THIS CAR
IS READY FOR FURTHER TESTING.
289
00:18:11,094 --> 00:18:14,364
A DRIVER STARTS UP THE CAR
FOR THE FIRST TIME.
290
00:18:14,396 --> 00:18:16,532
HE GUIDES IT
TO A ROLLING ROAD STATION
291
00:18:16,566 --> 00:18:19,236
IN THE DYNAMIC TESTING AREA.
292
00:18:20,870 --> 00:18:24,073
THE DRIVER FOLLOWS THE
DIRECTIONS OF A COMPUTER PROGRAM
293
00:18:24,107 --> 00:18:25,575
AND RUNS THE CAR
294
00:18:25,608 --> 00:18:28,279
THROUGH A BATTERY
OF DIFFERENT DRIVING MODES.
295
00:18:34,184 --> 00:18:36,286
THE PANAMERA ENTERS A BOOTH,
296
00:18:36,318 --> 00:18:37,921
WHERE HIGH-PRESSURE WATER JETS
297
00:18:37,953 --> 00:18:40,790
SIMULATE MONSOON CONDITIONS.
298
00:18:40,824 --> 00:18:42,692
NOZZLES POSITIONED ABOVE,
299
00:18:42,725 --> 00:18:45,128
BELOW, AND ON BOTH SIDES
OF THE CAR
300
00:18:45,162 --> 00:18:49,533
SHOOT SEVERAL HUNDRED GALLONS
OF WATER PER MINUTE.
301
00:18:49,567 --> 00:18:52,636
THE INTERIOR OF THE CAR
MUST BE COMPLETELY DRY,
302
00:18:52,668 --> 00:18:54,804
OR IT DOESN'T PASS THE TEST.
303
00:18:57,339 --> 00:19:00,443
AFTER LEAVING THE LEAKAGE
TEST BOOTH, THE DRIVER
304
00:19:00,476 --> 00:19:04,113
STEERS THE PANAMERA TO THE FINAL
STATIC CONTROL GATE,
305
00:19:04,147 --> 00:19:07,283
ALSO KNOWN
AS QUALITY GATE EIGHT.
306
00:19:08,985 --> 00:19:12,622
OUTSIDE, A DRIVER TAKES THE CAR
OVER A COBBLESTONE STRIP
307
00:19:12,655 --> 00:19:15,158
TO GAUGE INTERIOR NOISE.
308
00:19:16,593 --> 00:19:19,463
LEATHER UPHOLSTERY
TENDS TO BE SQUEAKY,
309
00:19:19,495 --> 00:19:22,499
BUT PORSCHE STRIVES
TO MINIMIZE THIS.
310
00:19:24,600 --> 00:19:27,069
THE TEST DRIVER
THEN STEERS THE PANAMERA
311
00:19:27,104 --> 00:19:30,007
UP THE SLOPE
OF A PURPOSE-BUILT TESTING HILL
312
00:19:30,039 --> 00:19:31,774
AND STOPS IT ON THE INCLINE
313
00:19:31,808 --> 00:19:35,179
TO CHECK THE HILL-HOLD FUNCTION
OF THE BRAKES.
314
00:19:38,347 --> 00:19:40,349
THEN HE TAKES IT OVER THE TOP
315
00:19:40,384 --> 00:19:44,121
AND TESTS THE CAR
ON THE DOWNWARD SLOPE.
316
00:19:44,154 --> 00:19:45,756
THE PANAMERA COMES STANDARD
317
00:19:45,789 --> 00:19:48,058
WITH THE PORSCHE TRACTION
MANAGEMENT SYSTEM,
318
00:19:48,090 --> 00:19:50,693
WHICH INCLUDES AUTOMATIC BRAKE
DIFFERENTIAL
319
00:19:50,726 --> 00:19:52,862
AND ANTISLIP REGULATION.
320
00:19:55,565 --> 00:19:57,834
IT'S NOW WORTHY OF DISPLAY
AT A VENUE
321
00:19:57,867 --> 00:20:01,171
LIKE THE LEIPZIG PORSCHE
CUSTOMER CARE CENTER.
322
00:20:03,306 --> 00:20:06,309
ONE WAY TO TELL THE DIFFERENT
PANAMERA MODELS APART
323
00:20:06,343 --> 00:20:10,381
IS BY LOOKING AT THE COLOR
OF THEIR BRAKE CALIPERS.
324
00:20:10,414 --> 00:20:12,316
YELLOW BRAKE CALIPERS
325
00:20:12,348 --> 00:20:17,186
SIGNIFY PORSCHE CERAMIC
COMPOSITE BRAKES, OR PCCBs.
326
00:20:17,221 --> 00:20:20,123
WITH ENHANCED PERFORMANCE,
FUEL ECONOMY, AND HANDLING,
327
00:20:20,155 --> 00:20:25,127
PCCBs CAN BE FITTED
ONTO ANY PANAMERA UPON REQUEST,
328
00:20:25,162 --> 00:20:29,332
BUT IT COMES STANDARD
ON THE TURBO S.
329
00:20:29,366 --> 00:20:33,002
WITH ITS 4.8-LITER
TWIN TURBO V-8 POWERHOUSE,
330
00:20:33,036 --> 00:20:35,539
THE TURBO S ACHIEVES
A MAXIMUM TORQUE
331
00:20:35,571 --> 00:20:37,540
OF 516 FOOT-POUNDS
332
00:20:37,574 --> 00:20:41,244
BETWEEN 2,500 AND 5,000 RPMs,
333
00:20:41,278 --> 00:20:45,549
ACCELERATES FROM ZERO TO 60
IN JUST 3.8 SECONDS,
334
00:20:45,581 --> 00:20:50,987
AND REACHES A TOP SPEED
OF 192 MILES PER HOUR.
335
00:20:52,187 --> 00:20:55,657
WHEN PORSCHE
INTRODUCED THE PANAMERA IN 2009,
336
00:20:55,692 --> 00:20:57,995
CAR FANS WERE SKEPTICAL
THAT A COMPANY
337
00:20:58,028 --> 00:20:59,363
FAMOUS FOR MANUFACTURING
338
00:20:59,395 --> 00:21:02,398
SOME OF THE MOST CELEBRATED
SPORTS CARS EVER BUILT
339
00:21:02,432 --> 00:21:06,669
COULD REALLY PULL OFF
A FOUR-DOOR LUXURY GRAND TOURER.
340
00:21:06,703 --> 00:21:10,106
BUT THE PANAMERA
HAS BEEN AN ENORMOUS SUCCESS.
341
00:21:10,138 --> 00:21:12,708
DESPITE FEELING LIKE A SEDAN,
342
00:21:12,741 --> 00:21:13,943
THE PANAMERA STILL
343
00:21:13,976 --> 00:21:17,080
LOOKS AND PERFORMS
LIKE A PORSCHE.
344
00:21:17,114 --> 00:21:18,481
IN OTHER WORDS,
345
00:21:18,514 --> 00:21:21,451
DRIVING A PANAMERA
IS LIKE DRIVING A SPORTS CAR,
346
00:21:21,484 --> 00:21:25,155
EXCEPT IT'S ROOMY, PLUSH,
AND HAS SPACE FOR LUGGAGE.
347
00:21:25,187 --> 00:21:28,357
AND LIKE ALL PORSCHES,
IT'S NOT JUST FAST,
348
00:21:28,392 --> 00:21:30,628
IT'S ALSO RELIABLE.
28202
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