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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS"...
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00:00:03,204 --> 00:00:05,296
GERMANY'S
MOST ICONIC SPORTS CAR --
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00:00:05,298 --> 00:00:08,191
THE PORSCHE 911.
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00:00:08,193 --> 00:00:11,560
-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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THE SIXTH LARGEST CITY
IN GERMANY -- STUTTGART --
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IS KNOWN AS THE CRADLE
OF THE AUTOMOBILE.
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00:00:28,906 --> 00:00:30,973
HERE, THE PORSCHE FAMILY
DESIGNS AND ASSEMBLES
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00:00:30,975 --> 00:00:33,768
SOME OF THE MOST FAMOUS
SPORTS CARS ON THE PLANET.
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00:00:33,770 --> 00:00:36,370
3,000 EMPLOYEES WORK
TO MANUFACTURE
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00:00:36,372 --> 00:00:40,732
PORSCHE'S MOST CELEBRATED CAR --
THE 911 COUPE.
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00:00:40,734 --> 00:00:44,528
IN 1963,
FERDINAND ALEXANDER PORSCHE
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00:00:44,530 --> 00:00:48,591
DESIGNED THE ORIGINAL 911
TO BE CALLED THE 901,
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00:00:48,593 --> 00:00:50,585
BUT THERE WAS A LITTLE
COMPETITION --
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00:00:50,587 --> 00:00:53,947
AN EXISTING MODEL
FROM A COMPETING AUTOMAKER
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00:00:53,949 --> 00:00:56,016
FORCED PORSCHE
TO RENAME THE CAR THE 911.
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00:00:56,018 --> 00:00:59,745
BY 1964, THE PORSCHE 911
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00:00:59,747 --> 00:01:03,540
WAS THE MOST DYNAMIC SPORTS CAR
OF THE PERIOD.
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00:01:03,542 --> 00:01:07,203
THIS CAR IS THE RESULT
OF A LONG HISTORY,
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00:01:07,205 --> 00:01:10,898
WITH THE CREATION
OF THE 1939 TYPE 64 --
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00:01:10,900 --> 00:01:13,501
A MODEL WITH
AN ALL-ALUMINUM CHASSIS
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00:01:13,503 --> 00:01:16,228
WHOSE FINAL VERSION
NEVER EMERGED.
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00:01:16,230 --> 00:01:17,630
PORSCHE CONSIDERS IT
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00:01:17,632 --> 00:01:19,457
THE GRANDFATHER
OF ALL THEIR CARS.
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00:01:20,827 --> 00:01:23,486
SINCE THE BEGINNING, THE COMPANY
HAS CREATED SPORTS CARS
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00:01:23,488 --> 00:01:26,782
AND CARS SPECIFICALLY
FOR MOTOR SPORTS.
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00:01:28,518 --> 00:01:32,713
THIS 911 IS THE MOST
SOPHISTICATED MODEL EVER BUILT,
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00:01:32,715 --> 00:01:35,441
WITH FUTURISTIC DESIGN,
ADVANCED TECHNOLOGIES,
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00:01:35,443 --> 00:01:40,171
IMPROVED ENGINE PERFORMANCE,
AND A LIGHTWEIGHT BODY.
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00:01:40,173 --> 00:01:41,972
IT'S A SUPERCAR THAT EPITOMIZES
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00:01:41,974 --> 00:01:45,101
TRADITION, INNOVATION,
AND A RACING PEDIGREE.
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00:01:48,198 --> 00:01:50,924
THE 911 STARTS WITH
THE BODYSHELL ASSEMBLY,
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00:01:50,926 --> 00:01:56,254
WHERE THE CHASSIS IS MADE
WITH MILD STEEL AND ALUMINUM.
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00:01:56,256 --> 00:01:59,149
PRODUCTION ISLANDS WITH
WELD-AND-TRANSFER ROBOTS
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00:01:59,151 --> 00:02:01,351
PUT TOGETHER
THE LARGEST PARTS --
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00:02:01,353 --> 00:02:04,213
NOTABLY, THE BASE
OF THE ENGINE BAY.
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00:02:04,215 --> 00:02:06,482
THE THREE ROBOTS
ARE PROGRAMMED TO WORK ON
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00:02:06,484 --> 00:02:09,143
ALL VARIANTS OF THE MODEL.
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00:02:09,145 --> 00:02:12,472
TWO WORKERS VERIFY THE QUALITY
OF THE SPOT WELDING.
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00:02:12,474 --> 00:02:17,035
INSPECTING EACH WELD,
THEY EXECUTE NECESSARY CHANGES,
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00:02:17,037 --> 00:02:19,596
AS WELL AS MEASURE THE DISTANCE
BETWEEN THE PARTS.
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00:02:21,834 --> 00:02:26,294
WHEN THE WORKERS COMPLETE
THEIR ASSESSMENT,
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00:02:26,296 --> 00:02:30,291
ROBOTS MOVE THE PARTS
TO ANOTHER WORKSTATION.
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00:02:30,293 --> 00:02:32,017
THE CAR'S BODYSHELL SIDE PANELS
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MOVE VIA A CONVEYOR LIFT
TO A WELDING STATION.
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00:02:36,249 --> 00:02:39,651
A WORKER INSTALLS THE PANELS
INTO A SECURE SECTION
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00:02:39,653 --> 00:02:42,711
WHERE ROBOTS WELD THE PARTS
WITH PRECISION.
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00:02:42,713 --> 00:02:45,573
SINCE THE CAR'S CHASSIS
IS A MonoKote STRUCTURE
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00:02:45,575 --> 00:02:47,709
RATHER THAN
A TRADITIONAL CHASSIS,
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00:02:47,711 --> 00:02:52,197
THE SIDE PANELS ARE ATTACHED
WITH THE BASE ALREADY COMPLETE.
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00:02:52,199 --> 00:02:54,866
AUTOMATED GUIDES
HOLD THE PANELS IN PLACE
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00:02:54,868 --> 00:02:57,495
WHILE THEY ARE WELDED
TO THE BASE.
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00:02:59,665 --> 00:03:03,059
THE BODYSHELL ASSEMBLY LINE
DELIVERS THE DOORS,
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00:03:03,061 --> 00:03:05,720
AND WELD ROBOTS SECURE THEM
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00:03:05,722 --> 00:03:08,881
BY PRECISELY WELDING
THE HINGES TO THE BODY.
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00:03:08,883 --> 00:03:10,883
HOWEVER, IT'S ONLY TEMPORARY,
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00:03:10,885 --> 00:03:14,679
SINCE THE DOORS WILL BE TAKEN
AWAY AFTER THE PAINTING PROCESS,
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00:03:14,681 --> 00:03:17,474
ONLY TO BE REATTACHED
ON THE VEHICLE ASSEMBLY LINE.
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00:03:17,476 --> 00:03:21,537
OTHER FRAME PARTS
IN THE CAR'S ROOFTOP
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00:03:21,539 --> 00:03:23,071
ARE WELDED
TO THE VEHICLE PLATFORM
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00:03:23,073 --> 00:03:25,566
IN THIS AUTOMATED
ASSEMBLY SECTION.
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00:03:28,904 --> 00:03:32,230
AN AUTOMATED LIFT MOVES
THE SKELETAL BODY OF THE CAR
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00:03:32,232 --> 00:03:36,995
TO ANOTHER STATION
FOR TREATMENT AND INSPECTION.
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00:03:40,224 --> 00:03:41,850
WORKERS INSPECT THE BODY
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00:03:41,852 --> 00:03:45,253
AND VERIFY THE STRENGTH AND
QUALITY OF THE MACHINED WELDS.
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00:03:45,255 --> 00:03:47,314
AFTERWARD,
THE STRUCTURE IS TAKEN
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00:03:47,316 --> 00:03:49,383
BY AN OVERHEAD CONVEYOR LIFT
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00:03:49,385 --> 00:03:53,411
TO ANOTHER ASSEMBLY LINE
FOR PARTS AND CLEANING.
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00:03:53,413 --> 00:03:57,041
AT THIS STAGE,
WORKERS INSTALL THE HOOD COVER
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00:03:57,043 --> 00:03:59,468
AND CARRY OUT MANUAL CLEANING.
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00:03:59,470 --> 00:04:02,529
USING SOFT CLOTHS
AND SPECIAL CLEANING AGENTS,
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00:04:02,531 --> 00:04:05,333
WORKERS ELIMINATE
ANY CONSTRUCTION DUST
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00:04:05,335 --> 00:04:07,327
ALONG THE BODY'S SURFACE.
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00:04:07,329 --> 00:04:09,329
THE FRAME,
WEIGHING 80 POUNDS LESS
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00:04:09,331 --> 00:04:11,522
THAN THE PREVIOUS GENERATION'S
CHASSIS,
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00:04:11,524 --> 00:04:14,851
IS MOVED BY A TRANSFER LIFTER
TO THE PAINT SHOP.
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00:04:16,555 --> 00:04:21,150
THE PAINTING PROCESS BEGINS
BY DIPPING THE BODY
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00:04:21,152 --> 00:04:23,878
INTO A BATH
OF CATHODIC DIP PRIMER.
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00:04:23,880 --> 00:04:25,612
CATHODIC PAINT ENHANCES
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00:04:25,614 --> 00:04:28,207
THE CORROSION RESISTANCE
OF THE CAR'S STRUCTURE,
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00:04:28,209 --> 00:04:31,135
BRINGING THE BODY CLOSER
TO AN IMMUNE STATE.
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00:04:34,039 --> 00:04:37,366
NEXT, A HIGH-PRESSURE SHOWER
RINSES THE FRAME
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00:04:37,368 --> 00:04:39,160
TO REMOVE ANY EXCESS PAINT
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00:04:39,162 --> 00:04:43,489
BEFORE THE FRAME DIPS INTO
THE PRIMER TREATMENT AGAIN.
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00:04:43,491 --> 00:04:45,758
SEVEN CONSECUTIVE
PRIMER BATHS ARE EMPLOYED
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00:04:45,760 --> 00:04:49,421
TO SHIELD THE CAR'S BODYSHELL
FROM RUST
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00:04:49,423 --> 00:04:51,182
AND OTHER ENVIRONMENTAL DAMAGE.
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00:04:55,446 --> 00:04:59,239
BY FLIPPING AND RETURNING
THE BODY INTO THE BASIN,
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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.
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00:05:04,239 --> 00:05:06,039
IT ALSO ELIMINATES ANY STREAKS
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00:05:06,041 --> 00:05:08,400
THAT MIGHT DEVELOP
AT INTERSECTIONS.
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00:05:10,804 --> 00:05:14,931
AFTER THE PAINT IS CURED
IN A 30-MINUTE DRYING PROCEDURE,
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00:05:14,933 --> 00:05:17,393
THE STRUCTURE MOVES
INTO ANOTHER ROOM
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00:05:17,395 --> 00:05:20,721
WHERE PAINT ROBOTS UNDERSEAL
WITH SEAM-SEALING PAINT,
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00:05:20,723 --> 00:05:23,591
WHICH CONSISTS OF A PVC COATING.
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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.
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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
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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,
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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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