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These are the user uploaded subtitles that are being translated: 1 00:00:01,802 --> 00:00:03,202 Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS"... 2 00:00:03,204 --> 00:00:05,296 GERMANY'S MOST ICONIC SPORTS CAR -- 3 00:00:05,298 --> 00:00:08,191 THE PORSCHE 911. 4 00:00:08,193 --> 00:00:11,560 -- Captions by VITAC -- www.vitac.com 5 00:00:11,562 --> 00:00:14,455 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:23,116 --> 00:00:26,309 THE SIXTH LARGEST CITY IN GERMANY -- STUTTGART -- 7 00:00:26,311 --> 00:00:28,904 IS KNOWN AS THE CRADLE OF THE AUTOMOBILE. 8 00:00:28,906 --> 00:00:30,973 HERE, THE PORSCHE FAMILY DESIGNS AND ASSEMBLES 9 00:00:30,975 --> 00:00:33,768 SOME OF THE MOST FAMOUS SPORTS CARS ON THE PLANET. 10 00:00:33,770 --> 00:00:36,370 3,000 EMPLOYEES WORK TO MANUFACTURE 11 00:00:36,372 --> 00:00:40,732 PORSCHE'S MOST CELEBRATED CAR -- THE 911 COUPE. 12 00:00:40,734 --> 00:00:44,528 IN 1963, FERDINAND ALEXANDER PORSCHE 13 00:00:44,530 --> 00:00:48,591 DESIGNED THE ORIGINAL 911 TO BE CALLED THE 901, 14 00:00:48,593 --> 00:00:50,585 BUT THERE WAS A LITTLE COMPETITION -- 15 00:00:50,587 --> 00:00:53,947 AN EXISTING MODEL FROM A COMPETING AUTOMAKER 16 00:00:53,949 --> 00:00:56,016 FORCED PORSCHE TO RENAME THE CAR THE 911. 17 00:00:56,018 --> 00:00:59,745 BY 1964, THE PORSCHE 911 18 00:00:59,747 --> 00:01:03,540 WAS THE MOST DYNAMIC SPORTS CAR OF THE PERIOD. 19 00:01:03,542 --> 00:01:07,203 THIS CAR IS THE RESULT OF A LONG HISTORY, 20 00:01:07,205 --> 00:01:10,898 WITH THE CREATION OF THE 1939 TYPE 64 -- 21 00:01:10,900 --> 00:01:13,501 A MODEL WITH AN ALL-ALUMINUM CHASSIS 22 00:01:13,503 --> 00:01:16,228 WHOSE FINAL VERSION NEVER EMERGED. 23 00:01:16,230 --> 00:01:17,630 PORSCHE CONSIDERS IT 24 00:01:17,632 --> 00:01:19,457 THE GRANDFATHER OF ALL THEIR CARS. 25 00:01:20,827 --> 00:01:23,486 SINCE THE BEGINNING, THE COMPANY HAS CREATED SPORTS CARS 26 00:01:23,488 --> 00:01:26,782 AND CARS SPECIFICALLY FOR MOTOR SPORTS. 27 00:01:28,518 --> 00:01:32,713 THIS 911 IS THE MOST SOPHISTICATED MODEL EVER BUILT, 28 00:01:32,715 --> 00:01:35,441 WITH FUTURISTIC DESIGN, ADVANCED TECHNOLOGIES, 29 00:01:35,443 --> 00:01:40,171 IMPROVED ENGINE PERFORMANCE, AND A LIGHTWEIGHT BODY. 30 00:01:40,173 --> 00:01:41,972 IT'S A SUPERCAR THAT EPITOMIZES 31 00:01:41,974 --> 00:01:45,101 TRADITION, INNOVATION, AND A RACING PEDIGREE. 32 00:01:48,198 --> 00:01:50,924 THE 911 STARTS WITH THE BODYSHELL ASSEMBLY, 33 00:01:50,926 --> 00:01:56,254 WHERE THE CHASSIS IS MADE WITH MILD STEEL AND ALUMINUM. 34 00:01:56,256 --> 00:01:59,149 PRODUCTION ISLANDS WITH WELD-AND-TRANSFER ROBOTS 35 00:01:59,151 --> 00:02:01,351 PUT TOGETHER THE LARGEST PARTS -- 36 00:02:01,353 --> 00:02:04,213 NOTABLY, THE BASE OF THE ENGINE BAY. 37 00:02:04,215 --> 00:02:06,482 THE THREE ROBOTS ARE PROGRAMMED TO WORK ON 38 00:02:06,484 --> 00:02:09,143 ALL VARIANTS OF THE MODEL. 39 00:02:09,145 --> 00:02:12,472 TWO WORKERS VERIFY THE QUALITY OF THE SPOT WELDING. 40 00:02:12,474 --> 00:02:17,035 INSPECTING EACH WELD, THEY EXECUTE NECESSARY CHANGES, 41 00:02:17,037 --> 00:02:19,596 AS WELL AS MEASURE THE DISTANCE BETWEEN THE PARTS. 42 00:02:21,834 --> 00:02:26,294 WHEN THE WORKERS COMPLETE THEIR ASSESSMENT, 43 00:02:26,296 --> 00:02:30,291 ROBOTS MOVE THE PARTS TO ANOTHER WORKSTATION. 44 00:02:30,293 --> 00:02:32,017 THE CAR'S BODYSHELL SIDE PANELS 45 00:02:32,019 --> 00:02:35,020 MOVE VIA A CONVEYOR LIFT TO A WELDING STATION. 46 00:02:36,249 --> 00:02:39,651 A WORKER INSTALLS THE PANELS INTO A SECURE SECTION 47 00:02:39,653 --> 00:02:42,711 WHERE ROBOTS WELD THE PARTS WITH PRECISION. 48 00:02:42,713 --> 00:02:45,573 SINCE THE CAR'S CHASSIS IS A MonoKote STRUCTURE 49 00:02:45,575 --> 00:02:47,709 RATHER THAN A TRADITIONAL CHASSIS, 50 00:02:47,711 --> 00:02:52,197 THE SIDE PANELS ARE ATTACHED WITH THE BASE ALREADY COMPLETE. 51 00:02:52,199 --> 00:02:54,866 AUTOMATED GUIDES HOLD THE PANELS IN PLACE 52 00:02:54,868 --> 00:02:57,495 WHILE THEY ARE WELDED TO THE BASE. 53 00:02:59,665 --> 00:03:03,059 THE BODYSHELL ASSEMBLY LINE DELIVERS THE DOORS, 54 00:03:03,061 --> 00:03:05,720 AND WELD ROBOTS SECURE THEM 55 00:03:05,722 --> 00:03:08,881 BY PRECISELY WELDING THE HINGES TO THE BODY. 56 00:03:08,883 --> 00:03:10,883 HOWEVER, IT'S ONLY TEMPORARY, 57 00:03:10,885 --> 00:03:14,679 SINCE THE DOORS WILL BE TAKEN AWAY AFTER THE PAINTING PROCESS, 58 00:03:14,681 --> 00:03:17,474 ONLY TO BE REATTACHED ON THE VEHICLE ASSEMBLY LINE. 59 00:03:17,476 --> 00:03:21,537 OTHER FRAME PARTS IN THE CAR'S ROOFTOP 60 00:03:21,539 --> 00:03:23,071 ARE WELDED TO THE VEHICLE PLATFORM 61 00:03:23,073 --> 00:03:25,566 IN THIS AUTOMATED ASSEMBLY SECTION. 62 00:03:28,904 --> 00:03:32,230 AN AUTOMATED LIFT MOVES THE SKELETAL BODY OF THE CAR 63 00:03:32,232 --> 00:03:36,995 TO ANOTHER STATION FOR TREATMENT AND INSPECTION. 64 00:03:40,224 --> 00:03:41,850 WORKERS INSPECT THE BODY 65 00:03:41,852 --> 00:03:45,253 AND VERIFY THE STRENGTH AND QUALITY OF THE MACHINED WELDS. 66 00:03:45,255 --> 00:03:47,314 AFTERWARD, THE STRUCTURE IS TAKEN 67 00:03:47,316 --> 00:03:49,383 BY AN OVERHEAD CONVEYOR LIFT 68 00:03:49,385 --> 00:03:53,411 TO ANOTHER ASSEMBLY LINE FOR PARTS AND CLEANING. 69 00:03:53,413 --> 00:03:57,041 AT THIS STAGE, WORKERS INSTALL THE HOOD COVER 70 00:03:57,043 --> 00:03:59,468 AND CARRY OUT MANUAL CLEANING. 71 00:03:59,470 --> 00:04:02,529 USING SOFT CLOTHS AND SPECIAL CLEANING AGENTS, 72 00:04:02,531 --> 00:04:05,333 WORKERS ELIMINATE ANY CONSTRUCTION DUST 73 00:04:05,335 --> 00:04:07,327 ALONG THE BODY'S SURFACE. 74 00:04:07,329 --> 00:04:09,329 THE FRAME, WEIGHING 80 POUNDS LESS 75 00:04:09,331 --> 00:04:11,522 THAN THE PREVIOUS GENERATION'S CHASSIS, 76 00:04:11,524 --> 00:04:14,851 IS MOVED BY A TRANSFER LIFTER TO THE PAINT SHOP. 77 00:04:16,555 --> 00:04:21,150 THE PAINTING PROCESS BEGINS BY DIPPING THE BODY 78 00:04:21,152 --> 00:04:23,878 INTO A BATH OF CATHODIC DIP PRIMER. 79 00:04:23,880 --> 00:04:25,612 CATHODIC PAINT ENHANCES 80 00:04:25,614 --> 00:04:28,207 THE CORROSION RESISTANCE OF THE CAR'S STRUCTURE, 81 00:04:28,209 --> 00:04:31,135 BRINGING THE BODY CLOSER TO AN IMMUNE STATE. 82 00:04:34,039 --> 00:04:37,366 NEXT, A HIGH-PRESSURE SHOWER RINSES THE FRAME 83 00:04:37,368 --> 00:04:39,160 TO REMOVE ANY EXCESS PAINT 84 00:04:39,162 --> 00:04:43,489 BEFORE THE FRAME DIPS INTO THE PRIMER TREATMENT AGAIN. 85 00:04:43,491 --> 00:04:45,758 SEVEN CONSECUTIVE PRIMER BATHS ARE EMPLOYED 86 00:04:45,760 --> 00:04:49,421 TO SHIELD THE CAR'S BODYSHELL FROM RUST 87 00:04:49,423 --> 00:04:51,182 AND OTHER ENVIRONMENTAL DAMAGE. 88 00:04:55,446 --> 00:04:59,239 BY FLIPPING AND RETURNING THE BODY INTO THE BASIN, 89 00:04:59,241 --> 00:05:01,376 THE PRIMER PAINT IS GUARANTEED TO REACH 90 00:05:01,378 --> 00:05:04,237 EVERY CAVITY AND CORNER. 91 00:05:04,239 --> 00:05:06,039 IT ALSO ELIMINATES ANY STREAKS 92 00:05:06,041 --> 00:05:08,400 THAT MIGHT DEVELOP AT INTERSECTIONS. 93 00:05:10,804 --> 00:05:14,931 AFTER THE PAINT IS CURED IN A 30-MINUTE DRYING PROCEDURE, 94 00:05:14,933 --> 00:05:17,393 THE STRUCTURE MOVES INTO ANOTHER ROOM 95 00:05:17,395 --> 00:05:20,721 WHERE PAINT ROBOTS UNDERSEAL WITH SEAM-SEALING PAINT, 96 00:05:20,723 --> 00:05:23,591 WHICH CONSISTS OF A PVC COATING. 97 00:05:23,593 --> 00:05:26,686 THIS LAYER OF PROTECTION WATERPROOFS ALL SEALS 98 00:05:26,688 --> 00:05:30,915 AND ELIMINATES ADDITIONAL POSSIBILITIES OF CORROSION. 99 00:05:34,946 --> 00:05:39,140 IN ANOTHER PAINT ROOM, THE BODY RECEIVES A FILLER COATING. 100 00:05:39,142 --> 00:05:42,035 PAINT ROBOTS APPLY THIS BASE COAT, 101 00:05:42,037 --> 00:05:46,898 WHICH SERVES TO PROTECT THE BODY FROM FLYING STONES. 102 00:05:46,900 --> 00:05:50,227 THE FILLER-COATING COLOR IS SELECTED BY THE CUSTOMER. 103 00:05:50,229 --> 00:05:55,491 ALL PAINT COLORS CAN BE REPRODUCED AT AN ADDED COST. 104 00:06:02,717 --> 00:06:04,250 THE STRUCTURE REQUIRES EIGHT LAYERS 105 00:06:04,252 --> 00:06:06,878 OF THE ENVIRONMENT-FRIENDLY, WATER-BASED FILLER COATING 106 00:06:06,880 --> 00:06:09,105 FOR FULL COVERAGE. 107 00:06:09,107 --> 00:06:10,841 ONCE THE PAINT IS CURED, 108 00:06:10,843 --> 00:06:13,135 THE BODYSHELL MOVES TO ANOTHER AREA 109 00:06:13,137 --> 00:06:16,805 WHERE ROBOTS APPLY TWO SOLVENT-BASED CLEAR COATS 110 00:06:16,807 --> 00:06:20,734 TO PROVIDE PROTECTION AGAINST SCRAPES AND SCRATCHES. 111 00:06:20,736 --> 00:06:23,662 A WORKER WEARING PROTECTIVE GLOVES 112 00:06:23,664 --> 00:06:26,124 TO AVOID ANY CONTACT WITH THE NEW PAINT 113 00:06:26,126 --> 00:06:28,793 INSTALLS THE COMPANY'S CREST ON THE HOOD 114 00:06:28,795 --> 00:06:32,222 WITH A SPECIALLY CRAFTED CLAMP, 115 00:06:32,224 --> 00:06:38,211 REVEALING THE SYMBOL OF STUTTGART'S PRIDE. 116 00:06:43,889 --> 00:06:47,715 Narrator: THE APPEAL OF THE PORSCHE 911 IS THE SILHOUETTE, 117 00:06:47,717 --> 00:06:50,444 BUT THE EXCITEMENT IS FROM A SIX-CYLINDER FLAT ENGINE 118 00:06:50,446 --> 00:06:53,313 PRODUCING 350 HORSEPOWER -- 119 00:06:53,315 --> 00:06:56,875 MORE THAN ENOUGH DRIVING FORCE FOR ANY ROAD. 120 00:06:59,071 --> 00:07:01,731 A WORKER DELIVERS PRE-PICKED ENGINE COMPONENTS 121 00:07:01,733 --> 00:07:04,934 SUCH AS THE CRANKCASE, THE CRANKSHAFT, AND PISTONS. 122 00:07:04,936 --> 00:07:08,662 USING A ROD-CONNECTING MACHINE, 123 00:07:08,664 --> 00:07:12,959 A WORKER ASSEMBLES PISTON RODS TO HEADS FOR A PERFECT MATCH. 124 00:07:15,088 --> 00:07:19,149 A LEAK-PROOF RING SURROUNDS EACH PISTON HEAD. 125 00:07:19,151 --> 00:07:21,818 THE WORKER GENTLY SLIDES THE COMBINED UNIT 126 00:07:21,820 --> 00:07:24,546 INTO THE CYLINDER BLOCK OF THE CRANKCASE. 127 00:07:24,548 --> 00:07:27,241 ONCE ALL THE PISTONS ARE SET, 128 00:07:27,243 --> 00:07:29,910 THE CYLINDER BLOCK MOVES TO A NEW WORKSTATION. 129 00:07:33,040 --> 00:07:35,767 WITH THE AID OF A LIFTING DEVICE, 130 00:07:35,769 --> 00:07:39,762 A WORKER LOWERS THE CRANKSHAFT ONTO A WORKTABLE. 131 00:07:39,764 --> 00:07:42,657 USING LUBRICATED CLAMPS, HE INSTALLS AND FASTENS 132 00:07:42,659 --> 00:07:46,394 THE CONNECTING RODS OF EACH PISTON TO THE CRANKSHAFT 133 00:07:46,396 --> 00:07:49,122 USING AN AIR-IMPACT SCREWDRIVER. 134 00:07:55,914 --> 00:07:57,714 AFTER SECURING THE PISTON RODS, 135 00:07:57,716 --> 00:08:00,376 THE WORKER ADDS METAL TIMING CHAINS TO THE CRANKSHAFT. 136 00:08:02,813 --> 00:08:06,541 TOO HEAVY TO HANDLE MANUALLY, USING A MECHANIZED LIFTER, 137 00:08:06,543 --> 00:08:08,134 A WORKER LOWERS THE CRANKSHAFT 138 00:08:08,136 --> 00:08:09,602 INTO THE CASING OF THE CRANKCASE, 139 00:08:09,604 --> 00:08:13,398 FIRMLY ATTACHING IT INTO POSITION. 140 00:08:13,400 --> 00:08:17,427 HE ALSO CHECKS THAT ALL MOVING PARTS ARE FUNCTIONAL. 141 00:08:24,353 --> 00:08:28,547 AS THE TWO SEPARATE CASES OF THE CRANKCASE 142 00:08:28,549 --> 00:08:30,749 ROLL INTO A CONTAINMENT ROOM, 143 00:08:30,751 --> 00:08:34,545 TRANSFER ROBOTS RAISE ONE PART ONTO THE OTHER. 144 00:08:36,508 --> 00:08:39,375 THE TWO PARTS ARE PRECISELY ALIGNED AND LINKED. 145 00:08:39,377 --> 00:08:42,637 THE SIX PISTONS ARE NOW IN 146 00:08:42,639 --> 00:08:46,133 HORIZONTALLY OPPOSITE POSITIONS OF ONE ANOTHER. 147 00:08:59,057 --> 00:09:01,649 A WORKER SHIFTS THE NEW ENGINE BLOCK 148 00:09:01,651 --> 00:09:04,511 INTO A CARRIER CALLED A CROSSMEMBER, 149 00:09:04,513 --> 00:09:07,380 WHICH TRANSPORTS THE ENGINE TO SELECT STATIONS 150 00:09:07,382 --> 00:09:10,075 FOR FURTHER ASSEMBLY. 151 00:09:10,077 --> 00:09:14,137 IN THE NEXT CIRCUIT, A WORKER INSTALLS A CYLINDER HEAD GASKET 152 00:09:14,139 --> 00:09:15,872 ONTO THE ENGINE BLOCK, 153 00:09:15,874 --> 00:09:20,269 WHICH WILL EXIST BETWEEN THE TWO HOUSING PARTS. 154 00:09:20,271 --> 00:09:22,263 THE ACCOMPANYING CYLINDER-HEAD SECTION, 155 00:09:22,265 --> 00:09:24,465 WHICH HOUSES THE CAMSHAFT, 156 00:09:24,467 --> 00:09:29,420 IS PRECISELY FASTENED INTO PLACE WITH AN AIR-IMPACT WRENCH. 157 00:09:29,422 --> 00:09:32,824 THE WORKER ROTATES THE ENGINE BLOCK 158 00:09:32,826 --> 00:09:35,418 AND INSTALLS A SECOND CYLINDER HEAD GASKET 159 00:09:35,420 --> 00:09:37,746 ONTO THE OTHER END OF THE ENGINE BLOCK. 160 00:09:40,350 --> 00:09:42,776 HE LOWERS ANOTHER LARGE PIECE OF THE ENGINE BLOCK 161 00:09:42,778 --> 00:09:44,710 WITH THE HELP OF A LIFTING DEVICE. 162 00:09:44,712 --> 00:09:49,174 THE WORKER ALSO PUTS LARGE BOLTS INTO SPECIFIC POSITIONS 163 00:09:49,176 --> 00:09:51,568 BEFORE SENDING THE NEAR-COMPLETE ENGINE 164 00:09:51,570 --> 00:09:54,797 TO ANOTHER SECTION INVOLVING MORE AUTOMATION. 165 00:09:57,367 --> 00:09:59,193 ON THE CROSSMEMBER, 166 00:09:59,195 --> 00:10:01,562 THE ENGINE BLOCK SHUTTLES TO A NEW WORKSTATION. 167 00:10:04,458 --> 00:10:08,053 AFTER THE DOUBLE-OVERHEAD CAMSHAFT IS COMPLETE, 168 00:10:08,055 --> 00:10:10,080 A ROBOT INSTALLS AND FASTENS A COVER. 169 00:10:10,082 --> 00:10:13,583 EACH SCREW IS CAREFULLY PUT INTO PLACE 170 00:10:13,585 --> 00:10:16,411 AND TURNED BY A MEASURED ROTATION. 171 00:10:16,413 --> 00:10:19,072 THE TURNING POWER IS EXTREMELY PRECISE 172 00:10:19,074 --> 00:10:21,274 FOR A WELL-SEALED COMPLETION, 173 00:10:21,276 --> 00:10:26,038 AVOIDING ANY UNNECESSARY TIGHTNESS OR DAMAGE. 174 00:10:30,336 --> 00:10:33,496 THE ENTIRE ENGINE ASSEMBLY ROTATES 175 00:10:33,498 --> 00:10:35,156 AND IS SET TO A NEW POSITION 176 00:10:35,158 --> 00:10:38,093 BEFORE ENTERING A CABINET FOR A COLD TEST. 177 00:10:42,224 --> 00:10:45,751 THIS ASSESSMENT DEVICE CHECKS THE NEW ENGINE WITH A LEAK TEST, 178 00:10:45,753 --> 00:10:48,445 FLOW TEST, AND PRESSURE TEST 179 00:10:48,447 --> 00:10:51,073 BY SIMULATING ITS FUNCTION WITH THE ASSISTANCE 180 00:10:51,075 --> 00:10:52,174 OF AN AUTOMATED AIR PUMP. 181 00:10:55,638 --> 00:10:57,838 WHEN THE TESTS ARE SUCCESSFUL, 182 00:10:57,840 --> 00:11:02,435 THE CENTRAL PART OF THE FLAT ENGINE IS COMPLETE. 183 00:11:02,437 --> 00:11:05,163 THE INSTALLATION OF TUBING IS NEXT. 184 00:11:05,165 --> 00:11:06,897 PLACEMENT OF THE INTAKE MANIFOLD, 185 00:11:06,899 --> 00:11:09,259 FOLLOWED BY EXHAUST MANIFOLD, 186 00:11:09,261 --> 00:11:13,155 COMPLETE THE 3.4-LITER V6 ENGINE ASSEMBLY. 187 00:11:17,986 --> 00:11:20,246 AT THE END OF THE LINE, 188 00:11:20,248 --> 00:11:23,582 A WORKER TRANSFERS THE MOTOR TO A ROBOTIC CART. 189 00:11:23,584 --> 00:11:26,477 USING GUIDANCE SIGNALS, THE CART TRAVELS 190 00:11:26,479 --> 00:11:29,305 TO THE PORSCHE 911 VEHICLE ASSEMBLY LINE. 191 00:11:39,758 --> 00:11:44,786 Narrator: THE INTERIOR OF THE PORSCHE 911 IS IMPRESSIVELY SOPHISTICATED, 192 00:11:44,788 --> 00:11:48,581 SUITED WITH THE FINEST LEATHER IN A VARIETY OF COLORS. 193 00:11:48,583 --> 00:11:52,111 THE CAR'S INTERIOR IS DESIGNED TO SUIT ANY CUSTOMER'S TASTE. 194 00:11:54,807 --> 00:11:56,941 IN THE UPHOLSTERY SHOP, 195 00:11:56,943 --> 00:12:00,269 LEATHER COLOR IS CHOSEN ACCORDING TO CUSTOMER CHOICE. 196 00:12:00,271 --> 00:12:02,663 MANUFACTURER-APPROVED COWHIDE, 197 00:12:02,665 --> 00:12:04,665 BOUGHT FROM CERTIFIED CATTLE HERDS, 198 00:12:04,667 --> 00:12:07,126 SITS ON AN OPTICAL SCANNING TABLE 199 00:12:07,128 --> 00:12:08,928 WHICH REMOVES ANY WRINKLES. 200 00:12:08,930 --> 00:12:13,358 WITHIN SECONDS, RECOGNITION BY A HIGH-DEFINITION CAMERA 201 00:12:13,360 --> 00:12:17,154 ASSESSES THE LEATHER'S SIZE, HOLES, AND MARKS IN DETAIL. 202 00:12:17,156 --> 00:12:22,209 USING A SPECIAL MOUSE, THE WORKER MARKS DEFECTS 203 00:12:22,211 --> 00:12:25,746 AND TRACES THOSE AREAS FOR FURTHER RECOGNITION. 204 00:12:25,748 --> 00:12:28,107 THIS ELIMINATES ANY IMPERFECTIONS 205 00:12:28,109 --> 00:12:31,369 AND IS ESSENTIAL TO CUTTING THE LEATHER INTO PIECES. 206 00:12:31,371 --> 00:12:34,764 THE CAR INTERIOR REQUIRES THE LEATHER OF FIVE COWS, 207 00:12:34,766 --> 00:12:39,961 AND IN THIS PROCESS, 40% OF THE LEATHER IS DISCARDED. 208 00:12:45,060 --> 00:12:49,854 ONCE COMPLETE, THE WORKER PLACES A CODE ON THE SKIN 209 00:12:49,856 --> 00:12:53,784 FOR IDENTIFICATION IN THE NEXT PROCESS. 210 00:12:53,786 --> 00:12:58,180 A WORKER SPREADS THE LEATHER ON AN AUTOMATED CUTTING TABLE. 211 00:12:58,182 --> 00:13:00,208 WITH THE IDENTIFICATION CODE, 212 00:13:00,210 --> 00:13:04,604 THE LEATHER WILL BE CUT INTO PATTERNED PIECES. 213 00:13:04,606 --> 00:13:07,999 THE COMPUTERIZED SYSTEM CONFIRMS THE CUTTING OF ALL PIECES 214 00:13:08,001 --> 00:13:11,328 WITH PRECISE CUSTOMIZATION. 215 00:13:11,330 --> 00:13:14,665 ON THE CUTTING TABLE, A VERY SMALL ecoJET 216 00:13:14,667 --> 00:13:16,758 SPRAYS WATER AT A HIGH PRESSURE, 217 00:13:16,760 --> 00:13:19,887 REPEATEDLY CREATING CONTOURS AND OUTLINES 218 00:13:19,889 --> 00:13:22,957 WITHOUT TEARING OR DAMAGING THE LEATHER. 219 00:13:33,044 --> 00:13:36,504 THE WORKER REMOVES ANY RESIDUE OR REMAINS, 220 00:13:36,506 --> 00:13:38,039 KEEPING THE PATTERNED PIECES 221 00:13:38,041 --> 00:13:41,568 SLICED BY THE ecoJET LEATHER CUTTER. 222 00:13:41,570 --> 00:13:43,369 WEARING WHITE GLOVES AND USING A SPATULA 223 00:13:43,371 --> 00:13:46,030 TO AVOID ANY WEAR ON THE MATERIAL, 224 00:13:46,032 --> 00:13:48,926 HE STACKS EACH NEW PIECE WITH OTHERS 225 00:13:48,928 --> 00:13:52,488 TO SEND TO THE SEWING ROOM. 226 00:13:55,860 --> 00:13:58,986 USING INDUSTRIAL SEWING MACHINES, 227 00:13:58,988 --> 00:14:02,515 SKILLED GARMENT WORKERS STITCH THE PIECES OF LEATHER TOGETHER 228 00:14:02,517 --> 00:14:05,443 WITH HIGH-STRENGTH NEEDLES AND THREAD. 229 00:14:05,445 --> 00:14:07,845 THE THREAD COLORS OFTEN MATCH OR CONTRAST 230 00:14:07,847 --> 00:14:10,807 THE PIGMENT OF THE LEATHER CUTOUTS. 231 00:14:12,478 --> 00:14:15,537 A WORKER PLACES THE UPPER UNIT OF THE DASHBOARD 232 00:14:15,539 --> 00:14:17,331 AND ITS LEATHER COUNTERPARTS, 233 00:14:17,333 --> 00:14:19,733 INFUSED WITH HIGH-STRENGTH BONDING GLUE, 234 00:14:19,735 --> 00:14:21,994 ONTO A CASTING UNIT. 235 00:14:21,996 --> 00:14:23,863 LOWERING A PRESSING DEVICE, 236 00:14:23,865 --> 00:14:27,225 IT ESTABLISHES A MARRIAGE OF THE MATERIALS. 237 00:14:27,227 --> 00:14:30,219 ENSURING THAT EACH SECTION OF THE LEATHER IS PROPERLY FITTED, 238 00:14:30,221 --> 00:14:34,149 THE WORKER PULLS THE MATERIAL TO SMOOTH IT ON ALL SIDES, 239 00:14:34,151 --> 00:14:37,944 MATCHING THE SEAMS TO THE FRAME. 240 00:14:37,946 --> 00:14:41,573 PRECISION FINISHING TOOLS, LIKE A DIRECTIONAL HEATER, 241 00:14:41,575 --> 00:14:44,642 CERTIFY THAT THE LEATHER IS PERFECTLY JOINED 242 00:14:44,644 --> 00:14:47,304 INTO EVERY CAVITY OF THE DASHBOARD FRAME 243 00:14:47,306 --> 00:14:49,599 WITHOUT OVERLOOKING ANY IMPERFECTIONS. 244 00:14:52,170 --> 00:14:54,628 THE WORKER PLACES THE DASHBOARD PART 245 00:14:54,630 --> 00:14:58,658 INTO A SPECIAL KILN TO FULLY DRY THE ADHESIVE 246 00:14:58,660 --> 00:15:00,426 AND PERFECTLY JOIN THE MATERIALS. 247 00:15:02,989 --> 00:15:07,317 WHEN DRIED, THE UNIT TRAVELS TO A NEW WORKSTATION. 248 00:15:07,319 --> 00:15:11,446 A WORKER PLACES A REAR PLASTIC PANEL 249 00:15:11,448 --> 00:15:14,307 ONTO THE INSIDE OF THE LEATHER-BOUND DASHBOARD. 250 00:15:14,309 --> 00:15:17,011 AN AUTOMATED COVER CONTAINS THE AREA 251 00:15:17,013 --> 00:15:21,473 WHILE A BONDING DEVICE BRACES THE PARTS WITH FASTENING TIES. 252 00:15:21,475 --> 00:15:24,134 THE SHAPE AND CONSTRUCTION OF THE UPPER DASHBOARD 253 00:15:24,136 --> 00:15:27,730 MAKE INSTALLING THE CAR'S DIALS AND SWITCHES EASY. 254 00:15:31,361 --> 00:15:35,221 ONCE THE FULLY UPHOLSTERED DASHBOARD IS PARTIALLY EQUIPPED, 255 00:15:35,223 --> 00:15:38,091 WORKERS SECURELY INSTALL IT INTO THE COCKPIT 256 00:15:38,093 --> 00:15:41,987 USING A MECHANICAL LIFTER AND AIR-IMPACT SCREWDRIVERS. 257 00:15:43,616 --> 00:15:47,509 THE CAR'S BODY MOVES ALONG THE VEHICLE ASSEMBLY LINE, 258 00:15:47,511 --> 00:15:49,779 PROTECTED BY VINYL COVERINGS. 259 00:15:51,974 --> 00:15:53,974 AND WITHOUT THE DOORS, 260 00:15:53,976 --> 00:15:57,503 INTERIOR INSTALLATION WORK IS MUCH EASIER TO EXECUTE, 261 00:15:57,505 --> 00:15:59,931 LIKE PLACING A GLASS SUNROOF. 262 00:16:01,634 --> 00:16:04,127 TWO WINDOW-ASSEMBLY ROBOTS ARE RESPONSIBLE 263 00:16:04,129 --> 00:16:07,990 FOR THE INSTALLATION OF THE FRONT AND REAR WINDSHIELDS. 264 00:16:07,992 --> 00:16:10,058 THE FIRST ROBOT APPLIES AN ADHESIVE PASTE 265 00:16:10,060 --> 00:16:11,986 AROUND THE GLASS EDGES 266 00:16:11,988 --> 00:16:16,248 AS THE SECOND ROBOT GENTLY ALIGNS THE WINDOW INTO POSITION 267 00:16:16,250 --> 00:16:20,277 USING INFRARED SENSORS FOR ACCURACY. 268 00:16:20,279 --> 00:16:23,214 AS A NEXT-LEVEL SPORTS CAR, THE CONSTRUCTION 269 00:16:23,216 --> 00:16:27,277 OF THE PORSCHE 911 CONTINUES ON MULTIPLE STORIES -- 270 00:16:27,279 --> 00:16:30,705 ALL WITHIN THE SAME BUILDING. 271 00:16:36,622 --> 00:16:39,616 Narrator: THE PORSCHE 911 ENGINE, TRANSMISSION, AND AXLES 272 00:16:39,618 --> 00:16:42,411 ARE MOUNTED BY A SYNCHRONOUS ELEVATING PLATFORM, 273 00:16:42,413 --> 00:16:44,613 WHERE THE PARTS ARE INSERTED INTO THE BODY. 274 00:16:44,615 --> 00:16:47,074 WORKERS CAN ALSO INSTALL CUSTOMIZED VARIANTS 275 00:16:47,076 --> 00:16:49,076 LIKE ALL-WHEEL DRIVE, CERAMIC BRAKES, 276 00:16:49,078 --> 00:16:50,636 OR A SPORTS CHASSIS. 277 00:16:51,706 --> 00:16:56,033 ADDING TO THE CAR'S ASSEMBLY, A WORKER AFFIXES THE GEARBOX 278 00:16:56,035 --> 00:17:00,730 TO THE 3.4-LITER V6 ENGINE BLOCK. 279 00:17:02,626 --> 00:17:06,227 BOTH PARTS ARE LOWERED WITH A HOIST ONTO A WORKSTATION 280 00:17:06,229 --> 00:17:08,255 WHERE SYSTEMS, INCLUDING THE DRIVETRAIN AND SUSPENSION, 281 00:17:08,257 --> 00:17:10,590 WILL JOIN THE MACHINERY. 282 00:17:10,592 --> 00:17:15,512 WORKERS ATTACH AND ALIGN THE EXHAUST SYSTEM. 283 00:17:17,250 --> 00:17:19,508 RAISED AND TRANSPORTED BY A SUSPENDED CONVEYOR LIFT, 284 00:17:19,510 --> 00:17:22,577 WORKERS SLOWLY LOWER THE BODY 285 00:17:22,579 --> 00:17:24,939 TO ENSURE THE ENGINE BLOCK, DAMPERS, AND SUSPENSION 286 00:17:24,941 --> 00:17:28,668 SLIDE DIRECTLY INTO THEIR DESIGNATED LOCATIONS 287 00:17:28,670 --> 00:17:31,529 WITHOUT ANY COMPLICATIONS. 288 00:17:31,531 --> 00:17:34,532 COMMONLY KNOWN AS THE MARRIAGE OF ELEMENTS, 289 00:17:34,534 --> 00:17:36,726 WORKERS BOLT THE DRIVETRAIN AND CHASSIS 290 00:17:36,728 --> 00:17:40,355 TO THE BODY OF THE CAR. 291 00:17:46,888 --> 00:17:49,681 ADDING TO THE CAR'S FLAIR AND SAFETY, 292 00:17:49,683 --> 00:17:52,342 TWO WORKERS MOUNT THE BUMPERS. 293 00:17:52,344 --> 00:17:54,612 ANOTHER WORKER, USING A PRESET MOLD, 294 00:17:54,614 --> 00:17:59,142 ATTACHES THE LEGENDARY NAMEPLATE WITH CARE AND PRECISION. 295 00:18:00,704 --> 00:18:03,304 A SIMPLE ADHESIVE AND FINISHING ROLLER 296 00:18:03,306 --> 00:18:04,464 KEEP IT TOGETHER. 297 00:18:06,702 --> 00:18:11,096 AND A QUICK WIPE-DOWN ADDS TO THE SHINE OF THE CAR'S IDENTITY. 298 00:18:12,725 --> 00:18:15,058 THE CAR NOW ENTERS THE FINAL STATIONS 299 00:18:15,060 --> 00:18:17,786 OF THE VEHICLE ASSEMBLY LINE. 300 00:18:17,788 --> 00:18:19,321 USING A LIFTING DEVICE, 301 00:18:19,323 --> 00:18:22,984 A WORKER MOUNTS THE TIRES AND RIMS ONTO EACH WHEEL PLATE. 302 00:18:22,986 --> 00:18:25,778 THE COMPANY'S ASSEMBLY PLANNING 303 00:18:25,780 --> 00:18:29,507 USES THE COST-EFFECTIVE "JUST IN TIME" STRATEGY, 304 00:18:29,509 --> 00:18:32,510 WHICH AVOIDS KEEPING ANY INVENTORY OF PARTS IN OVERSTOCK. 305 00:18:32,512 --> 00:18:38,266 AT THIS STATION, THE CAR REGAINS ITS DOORS. 306 00:18:38,268 --> 00:18:42,729 MANUFACTURED OFFSITE BY RECARO, A NAME SYNONYMOUS WITH RACING, 307 00:18:42,731 --> 00:18:46,359 THE SPORTY, LEATHER BUCKET SEATS ARE FIT INTO THE CABIN. 308 00:18:50,223 --> 00:18:52,690 AFTER BODY AND ELECTRICAL ADJUSTMENTS 309 00:18:52,692 --> 00:18:54,017 ON THE VEHICLE'S ASSEMBLY LINE, 310 00:18:54,019 --> 00:18:57,153 THE CAR WILL UNDERGO DRIVING TESTS. 311 00:19:00,017 --> 00:19:03,209 A WORKER DRIVES THE CAR ONTO TEST ROLLERS. 312 00:19:03,211 --> 00:19:06,170 COMPUTERIZED LASER SENSORS SCAN LABELS ON EACH WHEEL 313 00:19:06,172 --> 00:19:08,172 AND MONITOR THEIR MOVEMENT 314 00:19:08,174 --> 00:19:12,102 FOR ALIGNMENT, TIRE BALANCE, AND HANDLING QUALITIES. 315 00:19:17,927 --> 00:19:23,656 AT ANOTHER WORKSTATION, A WORKER SHAKES THE WHEELS LATERALLY 316 00:19:23,658 --> 00:19:25,525 TO MANUALLY CHECK THE AXLE ALIGNMENT. 317 00:19:25,527 --> 00:19:29,520 SENSORS AND COMPUTER SOFTWARE HELP PERFECT THE ADJUSTMENTS. 318 00:19:29,522 --> 00:19:32,182 NEXT, A WORKER ASSESSES THE ORIENTATION 319 00:19:32,184 --> 00:19:35,777 OF THE CAR'S OPTICAL BLOCKS AND LIGHT UNITS. 320 00:19:35,779 --> 00:19:40,407 A WORKER DRIVES THE CAR ONTO ANOTHER SET OF TEST ROLLERS. 321 00:19:40,409 --> 00:19:44,469 IN THIS EXERCISE, WHILE THE ACCELERATOR IS PRESSED, 322 00:19:44,471 --> 00:19:47,598 A DEVICE CALLED A DYNAMOMETER RECORDS MOTOR PERFORMANCE. 323 00:19:47,600 --> 00:19:49,801 IT MEASURES THE POWER AND TORQUE OUTPUT 324 00:19:49,803 --> 00:19:54,956 DELIVERED BY THE 3.4-LITER FLAT 6-CYLINDER ENGINE. 325 00:19:54,958 --> 00:19:58,693 A WATER-LEAKAGE TEST USES MID-PRESSURE SHOWERS 326 00:19:58,695 --> 00:20:02,622 AS A WORKER SEARCHES FOR LEAKS IN THE CABIN USING A FLASHLIGHT. 327 00:20:04,618 --> 00:20:08,812 WHEN THE EXTENSIVE DRIVE TESTS ARE SUCCESSFUL, 328 00:20:08,814 --> 00:20:10,613 THE CAR IS READY TO EXIT THE PLANT. 329 00:20:10,615 --> 00:20:14,176 THE FACTORY IN THE ZUFFENHAUSEN DISTRICT OF STUTTGART, GERMANY, 330 00:20:14,178 --> 00:20:17,771 PRODUCES MORE THAN 40,000 CARS PER YEAR -- 331 00:20:17,773 --> 00:20:21,100 TWICE THE AMOUNT SINCE THE EARLY '90s. 332 00:20:21,102 --> 00:20:23,561 ONLY VARIANTS OF THIS MODEL AND ANOTHER MODEL 333 00:20:23,563 --> 00:20:25,563 ARE ASSEMBLED HERE. 334 00:20:25,565 --> 00:20:27,165 INSTANTLY RECOGNIZABLE 335 00:20:27,167 --> 00:20:30,059 AND ORIGINALLY ENGINEERED FOR THE RACETRACK, 336 00:20:30,061 --> 00:20:34,055 THIS CAR CONTINUES TO STIR EMOTION AND GARNER ATTENTION, 337 00:20:34,057 --> 00:20:37,717 JUST AS IT DID IN ITS ORIGINAL YEAR. 338 00:20:37,719 --> 00:20:42,247 WITH A PERFECT LEATHER INTERIOR, ADVANCED TECHNOLOGY, 339 00:20:42,249 --> 00:20:45,843 AND A POWERFUL 3.4-LITER V6 ENGINE, 340 00:20:45,845 --> 00:20:48,137 THIS CAR IS ONE OF THE MOST CAPTIVATING SPORTS CARS 341 00:20:48,139 --> 00:20:51,540 IN THE ENTIRE WORLD. 342 00:20:51,542 --> 00:20:56,730 ALTHOUGH A GRAND DEPARTURE FROM THE FIRST 911, 343 00:20:56,732 --> 00:21:00,859 THIS CAR STILL RETAINS A LOT OF THE ORIGINAL STYLING 344 00:21:00,861 --> 00:21:02,995 WITH A MODERN EDGE 345 00:21:02,997 --> 00:21:06,956 AND THE GIFT OF NEW AERODYNAMICS. 346 00:21:06,958 --> 00:21:09,251 THIS CAR IS NO EXCEPTION TO THE RULE... 347 00:21:11,088 --> 00:21:14,615 ...WHICH HAS MADE IT CLASSICALLY APPEALING 348 00:21:14,617 --> 00:21:16,417 FOR MORE THAN 40 YEARS. 349 00:21:19,213 --> 00:21:21,706 DREAM CARS -- THE COMPACT PORSCHE 911 350 00:21:21,708 --> 00:21:25,501 IS POWERFULLY AGILE AND VISUALLY LEGENDARY 351 00:21:25,503 --> 00:21:28,605 WITHOUT COMPROMISE. 28766

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