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Narrator: TODAY,
ON "HOW IT'S MADE: DREAM CARS."
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00:00:03,604 --> 00:00:08,290
THE FERRARI FF, AN EXTREME
SUPER CAR FOR ALL SEASONS.
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00:00:08,292 --> 00:00:11,560
-- Captions by VITAC --
www.vitac.com
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00:00:11,562 --> 00:00:14,522
CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:22,982 --> 00:00:26,242
LOCATED IN THE COUNTRYSIDE
OF MARANELLO, ITALY,
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00:00:26,244 --> 00:00:27,377
THE FERRARI HEADQUARTERS
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IS A STATE-OF-THE-ART
INDUSTRIAL CITY.
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00:00:29,639 --> 00:00:31,639
THE SETTING, SCALE,
AND FACILITIES
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00:00:31,641 --> 00:00:33,900
ARE AS COMPELLING FOR VISITORS
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00:00:33,902 --> 00:00:36,436
AS THEY ARE FOR
THE MORE THAN 3,000 EMPLOYEES
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00:00:36,438 --> 00:00:39,265
WHO WORK AT THIS PLANT DAILY.
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00:00:39,267 --> 00:00:42,660
THE LIVELIHOOD OF THE COMPANY'S
STAFF IS TOP PRIORITY.
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00:00:42,662 --> 00:00:44,929
THE AUTOMAKER'S EMPLOYEES
COME FIRST
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00:00:44,931 --> 00:00:49,125
AND THE AMAZING CARS
THEY BUILD A CLOSE SECOND.
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00:00:49,127 --> 00:00:53,680
SINCE 1947, FERRARI HAS BEEN
WORLD FAMOUS FOR SPORTS CARS
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00:00:53,682 --> 00:00:57,150
AND FOR BEING THE MOST WINNING
TEAM IN FORMULA 1 RACING HISTORY
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00:00:57,152 --> 00:00:59,144
WITH MORE THAN 5,000 VICTORIES.
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00:00:59,146 --> 00:01:02,472
THE ICONIC FERRARI LOGO
WAS FIRST ADOPTED
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00:01:02,474 --> 00:01:05,075
BY THE ITALIAN WAR PILOT
FRANCESCO BARACCA,
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00:01:05,077 --> 00:01:08,270
WHO HAD THE PRANCING HORSE
PAINTED ON HIS AIRCRAFT.
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00:01:08,272 --> 00:01:10,498
THE AIRCRAFT WAS THEN GIVEN
AS A PRESENT
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00:01:10,500 --> 00:01:12,834
FROM HIS FAMILY TO ENZO FERRARI.
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00:01:12,836 --> 00:01:15,495
THE CLASSIC RED PAINT COLOR
WAS SIMPLY THE COLOR
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00:01:15,497 --> 00:01:18,156
ASSIGNED BY THE I.A.F.
TO ITALIAN GRAND PRIX CARS
25
00:01:18,158 --> 00:01:20,425
IN THE EARLY YEARS
OF THE LAST CENTURY.
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00:01:20,427 --> 00:01:21,760
IN THE LAST 20 YEARS,
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00:01:21,762 --> 00:01:24,554
FERRARI STARTED LAUNCHING
MORE NEW MODELS
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00:01:24,556 --> 00:01:26,581
WHILE RETAINING ITS CORE VALUES.
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00:01:26,583 --> 00:01:28,183
FERRARI IS NOW PRODUCING
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00:01:28,185 --> 00:01:31,645
THEIR FIRST EVER FOUR-SEAT,
ALL-WHEEL-DRIVE HATCHBACK --
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00:01:31,647 --> 00:01:33,380
THE FF.
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00:01:33,382 --> 00:01:36,642
THE FF HAS LARGER CABIN
AND LUGGAGE SPACE,
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00:01:36,644 --> 00:01:39,303
NOT TO MENTION A PATENTED
FOUR-WHEEL-DRIVE SYSTEM,
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00:01:39,305 --> 00:01:43,967
WHICH WEIGHS 50% LESS
THAN A TRADITIONAL VERSION.
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00:01:50,000 --> 00:01:53,260
THE FIRST MAJOR COMPONENT
OF THIS CAR
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00:01:53,262 --> 00:01:55,721
IS THE 12-CYLINDER ENGINE BLOCK.
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00:01:55,723 --> 00:01:57,656
MADE OF LIGHT-WEIGHT ALUMINUM,
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00:01:57,658 --> 00:02:02,153
IT IS THE CORE
OF THE 660-HORSEPOWER ENGINE.
39
00:02:04,015 --> 00:02:07,541
IN THE IN-HOUSE FOUNDRY
OF THE FACTORY,
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00:02:07,543 --> 00:02:10,878
A WORKER USES A HIGH-PRESSURE
BLOWER TO REMOVE ANY REMAINS
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00:02:10,880 --> 00:02:13,539
FROM CASTS USED TO CREATE
THE ESSENTIAL MOLDS
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00:02:13,541 --> 00:02:16,501
OF THE ALUMINUM ENGINE
CYLINDER BLOCKS.
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00:02:16,503 --> 00:02:19,363
USING HIGH-QUALITY CHEMICALS
AND SAND,
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00:02:19,365 --> 00:02:22,632
THE COMBINATION IS PRESSED
IN A GRAVITY-POWERED MOLD,
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00:02:22,634 --> 00:02:25,360
WHICH PRODUCES THE CASTS
OF THE INTERNAL INTAKE
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00:02:25,362 --> 00:02:28,289
AND EXHAUST PIPES
OF THE CYLINDER BLOCK HEAD.
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00:02:28,291 --> 00:02:31,883
THIS TECHNOLOGY GUARANTEES
THE BEST MECHANICAL PERFORMANCE
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00:02:31,885 --> 00:02:33,752
OF THE INDIVIDUAL PIECES
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00:02:33,754 --> 00:02:36,714
AND IS ALSO USED IN DEVELOPING
ENGINES OF PROTOTYPES
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00:02:36,716 --> 00:02:39,550
FOR FORMULA 1 RACE CARS.
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00:02:42,980 --> 00:02:45,907
THE WORKER MOVES THE SAND MOLDS
TO ANOTHER AREA
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00:02:45,909 --> 00:02:48,434
TO REMOVE
ANY UNNECESSARY PIECES.
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00:02:48,436 --> 00:02:51,571
USING A SMALL SAW, FILE,
AND A SANDING SPONGE,
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00:02:51,573 --> 00:02:55,334
THE PIECES ARE REMOVED
TO CONFORM TO THE CAST'S DESIGN,
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00:02:55,336 --> 00:02:59,129
NECESSARY TO CREATE THE INTERNAL
PIPES OF THE BLOCK HEAD.
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00:02:59,131 --> 00:03:02,792
THE SAND MOLDS WILL ALSO UNDERGO
A REGENERATION PROCESS,
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00:03:02,794 --> 00:03:07,822
WHERE THE SAND WILL BE REUSED
TO CREATE FUTURE MOLDS.
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00:03:12,020 --> 00:03:15,013
THE FINISHED SAND MOLDS ARRIVE
AT ANOTHER WORK STATION
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00:03:15,015 --> 00:03:16,739
WHERE THEY ARE ASSEMBLED.
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00:03:16,741 --> 00:03:19,542
A WORKER PLACES
THE BOTTOM COMPONENTS TOGETHER
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00:03:19,544 --> 00:03:21,136
BEFORE USING A LIFTING DEVICE
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00:03:21,138 --> 00:03:23,939
TO DELIVER THE LARGER
AND HEAVIER TOP SECTION,
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00:03:23,941 --> 00:03:27,401
COMPLETING
THE CYLINDER-BLOCK MATRIX.
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00:03:31,699 --> 00:03:33,957
ONCE THE GROUPING OF MOLDS
IS ALIGNED,
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00:03:33,959 --> 00:03:36,627
A SET OF TRANSPORT SPIKES
FROM A LIFTING DEVICE
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00:03:36,629 --> 00:03:39,222
USHER THE GROUPING
TO ANOTHER WORK STATION,
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00:03:39,224 --> 00:03:42,117
WHERE THE MOLDS ARE CURED
IN A HIGH-TEMPERATURE KILN
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00:03:42,119 --> 00:03:43,585
CALLED A WEIGHTING OVEN.
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00:03:43,587 --> 00:03:45,186
THE MOLTEN METAL WILL FLOW
70
00:03:45,188 --> 00:03:50,976
INTO ALL VACANT SPACES
LEFT FREE BY THE SAND MOLD.
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00:03:50,978 --> 00:03:54,571
THOUSANDS OF ALUMINUM INGOTS
CAN BE FOUND IN A STORAGE BAY
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00:03:54,573 --> 00:03:56,106
AT THE MARANELLO FACTORY.
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00:03:56,108 --> 00:03:59,935
THESE BLOCKS ARE MELTED AT
NEARLY 1,500 DEGREES FAHRENHEIT
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00:03:59,937 --> 00:04:02,997
IN ORDER TO BECOME
THE ENGINE CYLINDER BLOCKS.
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00:04:02,999 --> 00:04:05,065
AS MOLTEN ALUMINUM,
76
00:04:05,067 --> 00:04:07,193
THE SMELTED METAL IS POURED
THROUGH A FUNNEL
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00:04:07,195 --> 00:04:09,128
AND INJECTED INTO SAND CASTS,
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00:04:09,130 --> 00:04:12,924
SOON TO BECOME ONE OF THE MOST
INTEGRAL PARTS OF THE ENGINE.
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00:04:15,554 --> 00:04:19,080
THE WEIGHTING OVEN'S 1,400-
DEGREE TEMPERATURE IS CONSISTENT
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00:04:19,082 --> 00:04:23,244
IN ORDER TO PREVENT ANY DEFECTS
OR AIR BUBBLES WITHIN THE BLOCK.
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00:04:27,675 --> 00:04:29,875
ONCE THE MOLTEN ALUMINUM
HARDENS,
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00:04:29,877 --> 00:04:33,037
THE AUTOMATED CLAMPS
FROM THE KILN RELEASE THE MOLD,
83
00:04:33,039 --> 00:04:35,565
ALLOWING THE NEW ALUMINUM PARTS
TO COOL
84
00:04:35,567 --> 00:04:38,893
BEFORE REMOVAL FROM THE MOLDS.
85
00:04:38,895 --> 00:04:41,696
AN AUTOMATED LIFT REMOVES
THE FINISHED CASTS
86
00:04:41,698 --> 00:04:45,825
AND CYLINDER BLOCK
FROM THE HEATED STATION.
87
00:04:45,827 --> 00:04:49,288
A WORKER EXTRACTS THE ALUMINUM
PIECES FROM THE SAND MOLD,
88
00:04:49,290 --> 00:04:51,348
WHICH IS DISCARDED.
89
00:04:55,246 --> 00:04:58,914
QUALITY CONTROL IS IMPERATIVE
TO THE ASSEMBLY OF THE ENGINE.
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00:04:58,916 --> 00:05:00,441
AT THE FIRST WORK STATION,
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00:05:00,443 --> 00:05:03,369
A WORKER PLACES
THE CYLINDER BLOCK ON A TABLE,
92
00:05:03,371 --> 00:05:05,905
INSPECTING THE PART
WITH A SMALL FLASHLIGHT
93
00:05:05,907 --> 00:05:09,334
FOR ANY CRACKS OR IMPERFECTIONS
WITHIN THE CAVITIES.
94
00:05:09,336 --> 00:05:12,328
VERY LITTLE VARIATION
IN THE MOLD IS TOLERATED.
95
00:05:12,330 --> 00:05:13,730
FROM BEGINNING TO END,
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00:05:13,732 --> 00:05:16,925
UP TO 8,000 INSTRUMENTS ARE USED
TO CONTROL DIMENSIONS
97
00:05:16,927 --> 00:05:20,054
THROUGHOUT THE PROCESS
OF BUILDING THE CYLINDER BLOCK.
98
00:05:25,353 --> 00:05:28,279
THE ENGINE CYLINDER BLOCK
UNDERGOES A SECONDARY LOOK
99
00:05:28,281 --> 00:05:30,081
IN A RADIATION-SHIELDED CABINET
100
00:05:30,083 --> 00:05:32,942
OF A RADIOSCOPIC
INSPECTION SYSTEM.
101
00:05:32,944 --> 00:05:35,478
THIS FURTHER DETECTS
ANY POSSIBLE FLAWS
102
00:05:35,480 --> 00:05:38,840
IN THE CYLINDER BLOCK'S
CONSTRUCTION.
103
00:05:42,171 --> 00:05:45,364
AFTER GETTING THE GREEN LIGHT
FROM THE X-RAY INSPECTION,
104
00:05:45,366 --> 00:05:48,292
A WORKER MOUNTS THE CYLINDER
BLOCK ONTO A FIXTURE,
105
00:05:48,294 --> 00:05:51,828
WHERE IT TRAVELS INTO
A SMALL CABINET FOR REFINEMENT.
106
00:05:51,830 --> 00:05:53,756
THIS CNC DEVICE REMOVES
107
00:05:53,758 --> 00:05:55,891
ANY ADDITIONAL
AND UNWANTED MATERIALS
108
00:05:55,893 --> 00:05:57,318
WITHIN THE BLOCK'S CENTER
109
00:05:57,320 --> 00:06:02,582
USING HIGH-PRESSURE WATER
AND SAND GRAINS.
110
00:06:02,584 --> 00:06:05,443
AS A RESULT
OF THIS REFINING PROCESS,
111
00:06:05,445 --> 00:06:08,738
THE CYLINDER BLOCK LOOKS SLEEKER
THAN BEFORE.
112
00:06:08,740 --> 00:06:10,773
THE WORKER REMOVES
THE HOLDING BOLTS,
113
00:06:10,775 --> 00:06:14,402
AND THE PART IS READY
FOR THE NEXT WORK STATION.
114
00:06:14,404 --> 00:06:17,198
AT ANOTHER WORK TABLE
IN THE METROLOGY ROOM,
115
00:06:17,200 --> 00:06:20,267
A WORKER USES
A COMPUTERIZED MEASURING TOOL
116
00:06:20,269 --> 00:06:22,527
KNOWN AS A TOUCH PROBE TO VERIFY
117
00:06:22,529 --> 00:06:26,824
THE FERRARI FF CYLINDER BLOCK'S
TOLERANCE AND INTEGRITY.
118
00:06:28,594 --> 00:06:33,215
LATER IN THE SHOW, WE'LL SEE
MUCH MORE OF THIS ENGINE.
119
00:06:40,949 --> 00:06:43,075
Narrator:
THE MOST POPULAR FERRARIS
HAVE ALWAYS BEEN
120
00:06:43,077 --> 00:06:45,077
THE TWO-SEATER GRAN TURISMOS.
121
00:06:45,079 --> 00:06:47,838
ONLY 7,000 CARS
ARE PRODUCED YEARLY.
122
00:06:47,840 --> 00:06:50,900
THE FF IS VERY UNIQUE
TO THE LINEUP,
123
00:06:50,902 --> 00:06:54,896
BUT IT STILL MAINTAINS
THAT FASHIONABLE TRADITION.
124
00:06:56,500 --> 00:07:00,360
WITH EXCLUSIVE ACCESS
TO FERRARI'S FACTORY,
125
00:07:00,362 --> 00:07:04,957
WE UNCOVER THE FORMULA BEHIND
ITS RACING-INSPIRED FAMILY CAR.
126
00:07:04,959 --> 00:07:06,558
SHUTTLING TO A WORK STATION,
127
00:07:06,560 --> 00:07:08,852
THE CHASSIS LOWERS
INTO A SECTION
128
00:07:08,854 --> 00:07:13,783
WHERE A WORKER LOADS
PILLAR PARTS INTO WELD BRACES.
129
00:07:13,785 --> 00:07:16,577
THESE FIXTURES WILL ASSIST
IN THE INSTALLATION
130
00:07:16,579 --> 00:07:19,939
OF THE SIDE PANELS
AND THE ROOFING.
131
00:07:22,243 --> 00:07:24,002
WORKERS PLACE AND TIGHTLY FASTEN
132
00:07:24,004 --> 00:07:26,804
EVERY PILLAR AND SKELETAL BRANCH
OF THE BASE FRAME
133
00:07:26,806 --> 00:07:28,999
WITH THE ASSISTANCE
OF WELDING CLAMPS.
134
00:07:29,001 --> 00:07:32,060
ONCE LOCKED IN THE CLAMPS,
135
00:07:32,062 --> 00:07:36,323
WORKERS HAND-WELD
THE FRAME PARTS TOGETHER.
136
00:07:39,462 --> 00:07:41,887
UNLIKE OTHER
SPORTS CAR MANUFACTURERS,
137
00:07:41,889 --> 00:07:44,148
THIS COMPANY DOES NOT USE
WELD ROBOTS
138
00:07:44,150 --> 00:07:45,783
TO PUT THEIR CHASSIS TOGETHER.
139
00:07:47,420 --> 00:07:49,946
THE AUTOMAKER BOASTS
HAVING SOME OF THE BEST WELDERS
140
00:07:49,948 --> 00:07:52,340
IN THE WORLD.
141
00:07:53,811 --> 00:07:55,076
IN THE NEXT STEP,
142
00:07:55,078 --> 00:07:58,171
A WORKER INSTALLS SKIN PARTS
OF THE BASE FRAME
143
00:07:58,173 --> 00:08:02,167
TO THE SIDE-
AND ROOF-SUPPORT PILLARS.
144
00:08:02,169 --> 00:08:04,036
THE WORKER LOWERS
A LARGE SUPPORT FIXTURE
145
00:08:04,038 --> 00:08:07,697
WITH SUPPORT CLAMPS TO HOLD
THE BODY PARTS IN POSITION.
146
00:08:07,699 --> 00:08:10,760
THIS IS SO HE CAN WELD
THE PIECES TO THE SUPPORT BEAMS
147
00:08:10,762 --> 00:08:13,187
WITH EASE AND PRECISION.
148
00:08:13,189 --> 00:08:16,190
ONCE AGAIN,
THE WELDING IS DONE BY HAND,
149
00:08:16,192 --> 00:08:19,652
FURTHER DISPLAYING THE COMPANY'S
ALLEGIANCE TO FINE CRAFTSMANSHIP
150
00:08:19,654 --> 00:08:22,447
AND ATTENTION TO EVERY DETAIL.
151
00:08:22,449 --> 00:08:26,443
WHEN WELDING IS COMPLETE
AND COOLED,
152
00:08:26,445 --> 00:08:28,311
THE REMAINING RESIDUE NEEDS
TO BE REMOVED
153
00:08:28,313 --> 00:08:30,405
TO CREATE A FINISHED APPEARANCE.
154
00:08:30,407 --> 00:08:36,737
A WORKER GRINDS THE EXCESS METAL
WITH A HEAVY-DUTY GRINDER.
155
00:08:36,739 --> 00:08:39,798
USING A FLEXIBLE FILER HOLDER
AND MILL-CUT FILE,
156
00:08:39,800 --> 00:08:42,794
WHICH CUTS AWAY UNWANTED RESIDUE
ON THE BARE METAL,
157
00:08:42,796 --> 00:08:45,688
THE WORKER SHAPES AND SMOOTHES
THE BODY'S SURFACE.
158
00:08:45,690 --> 00:08:48,291
IN THIS PART OF THE PROCESS,
159
00:08:48,293 --> 00:08:51,419
HE PREPARES THE WELDED AREAS
FOR MACHINE-SANDING
160
00:08:51,421 --> 00:08:57,083
AND FEATHER-EDGING
FOR A SMOOTH AND GLOSSY FINISH.
161
00:08:57,085 --> 00:09:02,572
USING A HIGH-POWERED SANDER, THE
WORKER POLISHES THE WELDED AREA,
162
00:09:02,574 --> 00:09:04,841
CREATING
A PERFECTLY SMOOTH FINISH,
163
00:09:04,843 --> 00:09:07,937
MAKING ANY WELDING UNNOTICEABLE.
164
00:09:13,703 --> 00:09:17,563
WITH MOST BODY PARTS ON BOARD,
WORKERS INSPECT THE SHELL
165
00:09:17,565 --> 00:09:19,958
IN A ROOM WITH
SPECIALLY ENHANCED LIGHTING,
166
00:09:19,960 --> 00:09:22,853
WHICH HELPS IDENTIFY ANY ERRORS.
167
00:09:22,855 --> 00:09:25,788
A WORKER MARKS THE AREAS
THAT REQUIRE MORE FINESSING
168
00:09:25,790 --> 00:09:28,851
BEFORE ENTERING
THE PLANT'S PAINT SHOP.
169
00:09:28,853 --> 00:09:31,445
THE PAINT SHOP IS
ONE LARGE SECTION
170
00:09:31,447 --> 00:09:35,041
WITH THREE STAGGERED ROOMS
FOR DIFFERENT OPERATIONS.
171
00:09:35,043 --> 00:09:38,603
THE PAINTING PROCESS TAKES
ROUGHLY TWO AND A HALF DAYS.
172
00:09:40,807 --> 00:09:43,466
THE CAR ENTERS A ROOM
FOR ELECTROCOATING,
173
00:09:43,468 --> 00:09:46,068
THE PRIMARY
CORROSION-PROTECTION LAYER.
174
00:09:46,070 --> 00:09:50,198
IN A TUNNEL, THE CAR'S BODY IS
IMMERSED IN 11 LIQUID TANKS
175
00:09:50,200 --> 00:09:53,926
WITHOUT ANY HUMAN INTERVENTION.
176
00:09:53,928 --> 00:09:58,089
AFTER THE ELECTROCOATING
PROCESS,
177
00:09:58,091 --> 00:10:02,486
WORKERS APPLY A CLEANING AGENT
TO THE BODY TO CLEAN, DEGREASE,
178
00:10:02,488 --> 00:10:05,080
AND REMOVE ANY RESIDUE
ON THE SURFACE OF THE VEHICLE,
179
00:10:05,082 --> 00:10:08,409
PREPARING IT
FOR THE NEXT PAINTING STAGE.
180
00:10:08,411 --> 00:10:13,673
ANY DIRT OR IMPURITIES CAN BE AN
ENEMY IN THE PAINTING PROCESS.
181
00:10:18,772 --> 00:10:20,763
IN THIS PHASE,
182
00:10:20,765 --> 00:10:24,226
WEARING PROTECTIVE GARMENTS,
WORKERS MIST A TOP COAT
183
00:10:24,228 --> 00:10:27,654
THROUGHOUT THE EXTERIOR
AND INTERIOR OF THE BODY.
184
00:10:27,656 --> 00:10:31,459
THIS LAYER ACTS AS A TRANSLUCENT
COAT OF PAINT AND SEALER,
185
00:10:31,461 --> 00:10:34,720
PREVENTING CORROSION AND RUST
AND ALLOWING BETTER ADHESION
186
00:10:34,722 --> 00:10:36,981
FOR THE CHOSEN PAINT COLOR
TO THE BODY.
187
00:10:41,712 --> 00:10:45,006
MOVING AHEAD,
TWO ROBOTS CONTINUE THE PROCESS,
188
00:10:45,008 --> 00:10:47,676
COATING THE ENTIRE BODY
WITH A CLEAR COAT
189
00:10:47,678 --> 00:10:50,404
OF A CUSTOMER-DESIRED
PAINT COLOR.
190
00:10:50,406 --> 00:10:53,999
EACH ROBOTIC ARM MISTS THE FRAME
191
00:10:54,001 --> 00:10:56,927
WITH TIMELY PRECISION
AND MAXIMUM UNIFORMITY.
192
00:10:56,929 --> 00:10:59,463
CLEAR-COATING IS
THE MOST IMPORTANT PART
193
00:10:59,465 --> 00:11:01,223
OF THE PAINTING PROCESS.
194
00:11:01,225 --> 00:11:04,752
THIS LAYER OF PAINT IS DESIGNED
TO RESIST ENVIRONMENTAL MARKS,
195
00:11:04,754 --> 00:11:10,216
BIRD DROPPINGS, CAR WASHES,
AND OTHER OUTSIDE INFLUENCES.
196
00:11:12,019 --> 00:11:14,479
THE CLEAR COAT,
COMBINED WITH THE ELECTROCOAT,
197
00:11:14,481 --> 00:11:16,214
FORMS THE BODY'S TOP COAT,
198
00:11:16,216 --> 00:11:21,503
WHICH GIVES THE CAR'S SHELL
ITS OVERALL APPEARANCE.
199
00:11:21,505 --> 00:11:25,299
ONCE THE BODY RECEIVES ALL
OF ITS PROTECTIVE PAINT LAYERS,
200
00:11:25,301 --> 00:11:28,235
IT MOVES TO A SPECIALIZED
COMPARTMENT FOR CURING.
201
00:11:28,237 --> 00:11:33,257
UNIFORM HEATING OF 285 DEGREES
FAHRENHEIT FOR 24 MINUTES
202
00:11:33,259 --> 00:11:35,459
CREATES
THE IDEAL DRYING CONDITIONS
203
00:11:35,461 --> 00:11:38,587
BEFORE CONTINUING
TO THE NEXT STEP.
204
00:11:38,589 --> 00:11:43,117
TWO ROBOTS SPRAY THE LAST
TRANSPARENT COAT OF PAINT,
205
00:11:43,119 --> 00:11:47,314
PERFECTLY COVERING THE BODY.
206
00:11:47,316 --> 00:11:49,115
ONCE THE PROCESS IS FINISHED,
207
00:11:49,117 --> 00:11:51,977
THE BODY WILL MEET
ITS MOTORIZED COUNTERPART
208
00:11:51,979 --> 00:11:56,774
AND BECOME THE UNIQUE FOUR-
WHEEL-DRIVE FERRARI SPORTS CAR.
209
00:12:05,330 --> 00:12:08,489
Narrator: THE GAS
DIRECT-INJECTION V-12 ENGINE
210
00:12:08,491 --> 00:12:12,285
IS THE HAND-CRAFTED HEART OF
THE FOUR-WHEEL-DRIVE FERRARI FF.
211
00:12:12,287 --> 00:12:14,946
ONE ENGINE TAKES FIVE DAYS
TO ASSEMBLE
212
00:12:14,948 --> 00:12:18,943
BY AN EXPERIENCED WORKER WHO
SIGNS AN ASSEMBLY CERTIFICATE
213
00:12:18,945 --> 00:12:20,744
DELIVERED TO CUSTOMERS.
214
00:12:20,746 --> 00:12:24,239
FERRARI'S MECHANICAL WORKSHOP
IS COMPRISED OF 15 AREAS
215
00:12:24,241 --> 00:12:26,775
CONTAINING WORK STATIONS
WITH MACHINE TOOLS,
216
00:12:26,777 --> 00:12:29,237
OFFICES, AND TWO GREEN AREAS.
217
00:12:29,239 --> 00:12:31,104
IT'S A SPACE WHERE TECHNOLOGY
218
00:12:31,106 --> 00:12:35,626
AND ENVIRONMENTAL SUSTAINABILITY
COEXIST.
219
00:12:35,628 --> 00:12:38,229
IN THIS PARTICULAR ROOM,
TWO ASSEMBLY ROBOTS
220
00:12:38,231 --> 00:12:40,790
AFFECTIONATELY NAMED
ROMEO AND JULIET
221
00:12:40,792 --> 00:12:44,720
INSTALL VALVE-SET INSERTS
INTO THE CYLINDER HEAD --
222
00:12:44,722 --> 00:12:48,449
AN OPERATION KNOWN AS
THE THERMAL INTERFACE PROCESS.
223
00:12:51,746 --> 00:12:54,780
ONE ROBOT PASSES THE RING
TO THE OTHER ROBOT,
224
00:12:54,782 --> 00:12:57,408
WHICH PLACES THE RING
INTO THE HEAD.
225
00:12:57,410 --> 00:13:01,670
THE VALVE SETS COOL
AND SHRINK 40 TO 60 MICRONS
226
00:13:01,672 --> 00:13:06,267
IN LIQUID NITROGEN COOLED
AT -320 DEGREES FAHRENHEIT.
227
00:13:06,269 --> 00:13:08,728
WHEN THE VALVES ARE WARMED UP
TO ROOM TEMPERATURE,
228
00:13:08,730 --> 00:13:13,258
WHICH INCREASES ITS VOLUME BY
0.12 TO 0.15 SQUARE MILLIMETERS,
229
00:13:13,260 --> 00:13:17,888
THEY CLASP TIGHTLY INTO PLACE.
230
00:13:17,890 --> 00:13:22,017
THIS AREA IS KNOWN AS
THE 12-CYLINDER ASSEMBLY LINE,
231
00:13:22,019 --> 00:13:24,153
COMPOSED OF FIVE SECTIONS.
232
00:13:24,155 --> 00:13:25,613
IN THE FIRST SECTION,
233
00:13:25,615 --> 00:13:29,208
A WORKER MOVES THE 12-CYLINDER
ENGINE BLOCK TO A TABLE
234
00:13:29,210 --> 00:13:31,944
TO INSTALL THE CYLINDER SLEEVES.
235
00:13:31,946 --> 00:13:35,373
USING A RUBBER MALLET, SHE
HAMMERS THE SLEEVES INTO PLACE
236
00:13:35,375 --> 00:13:37,834
WITH THE ASSISTANCE
OF A SUPPORT FIXTURE,
237
00:13:37,836 --> 00:13:42,897
WHICH LIFTS AND RELEASES EACH
SLEEVE INTO THE BLOCK PIPES.
238
00:13:42,899 --> 00:13:46,426
THAT ACTION IS REPEATED UNTIL
SHE INSTALLS THE 12 LINERS.
239
00:13:46,428 --> 00:13:50,122
THE CYLINDER LINERS SERVE AS
THE INNER WALL OF THE CYLINDER,
240
00:13:50,124 --> 00:13:52,991
FORMING A SLIDING SURFACE
FOR THE PISTON RINGS
241
00:13:52,993 --> 00:13:56,920
WHILE RETAINING
THE LUBRICANT WITHIN.
242
00:13:56,922 --> 00:13:59,382
A WORKER DOUBLE CHECKS
243
00:13:59,384 --> 00:14:02,577
THAT THE SLEEVES ARE ALIGNED
WITH THE BLOCK'S PIPES
244
00:14:02,579 --> 00:14:05,872
BY TAPPING THE ENDS
WITH A RUBBER MALLET.
245
00:14:05,874 --> 00:14:08,942
A WORKER ROTATES THE ENGINE
CYLINDER BLOCK ON A LIFT,
246
00:14:08,944 --> 00:14:10,401
OILING THE CAM BEARINGS
247
00:14:10,403 --> 00:14:15,065
BEFORE PLACING THE CRANKSHAFT
INTO POSITION.
248
00:14:20,331 --> 00:14:22,490
ONCE THE CRANKSHAFT IS IN PLACE,
249
00:14:22,492 --> 00:14:24,625
THE WORKER INSTALLS
CONTAINMENT CLAMPS
250
00:14:24,627 --> 00:14:28,021
TO KEEP THE ROTATING PART
IN POSITION.
251
00:14:28,023 --> 00:14:30,414
HE ROTATES
THE ENTIRE CYLINDER BLOCK
252
00:14:30,416 --> 00:14:31,950
IN PREPARATION
253
00:14:31,952 --> 00:14:36,079
FOR THE INSTALLATION
OF THE ENGINE'S PISTONS.
254
00:14:36,081 --> 00:14:39,841
THE ENGINE PISTONS ARE MADE
FOR MAXIMUM EFFICIENCY,
255
00:14:39,843 --> 00:14:42,177
USING THE SAME RESEARCH
AND DEVELOPMENT
256
00:14:42,179 --> 00:14:46,106
FOR FERRARI'S
FORMULA 1 RACING CARS.
257
00:14:46,108 --> 00:14:49,769
A WORKER INSTALLS
EACH OF THE 12 PISTONS BY HAND
258
00:14:49,771 --> 00:14:52,696
AND VERIFIES
THAT THEY ARE INSERTED CORRECTLY
259
00:14:52,698 --> 00:14:56,993
WITH THE ASSISTANCE
OF A CYLINDRICAL GUIDE.
260
00:14:56,995 --> 00:14:59,454
ONCE FINISHED,
THIS 12-CYLINDER ENGINE,
261
00:14:59,456 --> 00:15:01,790
ALONG WITH
ITS OTHER RUNNING COMPONENTS,
262
00:15:01,792 --> 00:15:03,250
WILL ALLOW THE CAR
263
00:15:03,252 --> 00:15:07,446
TO REACH A TOP SPEED
OF OVER 200 MILES AN HOUR.
264
00:15:09,449 --> 00:15:12,676
THE 12-CYLINDER ENGINE SPENDS
ROUGHLY 62 MINUTES
265
00:15:12,678 --> 00:15:14,210
AT EACH STATION.
266
00:15:14,212 --> 00:15:17,807
IT TAKES APPROXIMATELY FIVE DAYS
FOR ASSEMBLY.
267
00:15:20,803 --> 00:15:23,296
ALMOST COMPLETE,
THE ENGINE REQUIRES
268
00:15:23,298 --> 00:15:26,799
THE PROPER ELECTRICAL WIRING
AND MECHANICAL TUBING.
269
00:15:26,801 --> 00:15:29,727
A WORKER METICULOUSLY PLACES
A WEB OF TUBES
270
00:15:29,729 --> 00:15:32,422
ONTO THEIR PROPER OUTLETS.
271
00:15:35,586 --> 00:15:38,220
ONCE THE WIRES AND TUBES
ARE CONNECTED,
272
00:15:38,222 --> 00:15:43,684
HE SECURES THEM WITH HIGH-
STRENGTH SCREWS AND FASTENERS.
273
00:15:43,686 --> 00:15:47,279
THE VELOCITY STACK IS PART OF
THE ENGINE'S AIR-INTAKE SYSTEM,
274
00:15:47,281 --> 00:15:50,107
WHICH ALLOWS FOR
A SMOOTH AND EVEN FLOW OF AIR
275
00:15:50,109 --> 00:15:51,442
AT HIGH VELOCITIES.
276
00:15:51,444 --> 00:15:53,436
THE WORKER ADDS THE STACK
277
00:15:53,438 --> 00:15:56,564
AND BOLTS IT ON EACH SIDE
USING AN AIR-IMPACT WRENCH.
278
00:15:56,566 --> 00:16:00,627
THIS CAR'S ENGINE DELIVERS
A SENSATIONAL TONE
279
00:16:00,629 --> 00:16:03,029
BECAUSE THE INTAKE NOISE
IS CHANNELED
280
00:16:03,031 --> 00:16:05,657
FROM FILTER CASINGS
INTO THE CABIN,
281
00:16:05,659 --> 00:16:08,919
MAKING AN UNMISTAKABLE SOUND
WITHOUT BEING LOUD.
282
00:16:08,921 --> 00:16:12,055
THE WORKER USES
A MOTORIZED ASSEMBLY SHUTTLE
283
00:16:12,057 --> 00:16:15,184
TO TRANSPORT THE ENGINE
JUST A FEW FEET AWAY,
284
00:16:15,186 --> 00:16:18,779
WHERE THE VELOCITY STACK WILL
RECEIVE ITS STYLISH COVERS.
285
00:16:18,781 --> 00:16:24,010
THIS COMPLETES THE ASSEMBLY
OF THE HIGH-END V-12 ENGINE.
286
00:16:24,012 --> 00:16:30,399
THE 6.3-LITER, V-12, DIRECT-
INJECTION, 6,262-cc ENGINE,
287
00:16:30,401 --> 00:16:36,130
DELIVERS A POWER OUTPUT
OF 660 HORSEPOWER AT 8,000 RPM,
288
00:16:36,132 --> 00:16:41,887
WITH MAXIMUM TORQUE
OF 504 POUND-FEET AT 6,000 RPM.
289
00:16:41,889 --> 00:16:46,350
BUILT FOR IMPRESSIVE RESPONSE
AND UNPARALLELED PERFORMANCE,
290
00:16:46,352 --> 00:16:49,878
THIS ENGINE IS SOLELY MADE
FOR THE FF MODEL.
291
00:16:49,880 --> 00:16:51,613
AFTER THE ASSEMBLY,
292
00:16:51,615 --> 00:16:55,910
THE ENGINE UNDERGOES A SERIES
OF DRIVING AND EMISSION TESTS.
293
00:17:01,839 --> 00:17:04,532
Narrator: WITHIN FERRARI'S
ASSEMBLY-LINE BUILDING,
294
00:17:04,534 --> 00:17:06,133
THE OVERHEAD TRANSPORT CAROUSEL
295
00:17:06,135 --> 00:17:08,861
IS COMPLETELY
ERGONOMICALLY ADVANCED.
296
00:17:08,863 --> 00:17:12,490
IT'S PROGRAMMED TO ROTATE
AND ADJUST FF BODY SHELLS
297
00:17:12,492 --> 00:17:15,986
TO EASILY FACE WORKERS
OF ANY HEIGHT.
298
00:17:17,289 --> 00:17:19,288
THIS SECTION
OF THE ASSEMBLY LINE
299
00:17:19,290 --> 00:17:21,483
IS WHERE WORKERS INSTALL
MOBILE PARTS,
300
00:17:21,485 --> 00:17:25,078
LIKE DOORS AND TRUNK LIDS,
AS WELL AS INTERIOR PARTS.
301
00:17:25,080 --> 00:17:28,841
OPERATION AND QUALITY-CONTROL
TESTS ARE EXECUTED
302
00:17:28,843 --> 00:17:31,176
BEFORE THE BODY MOVES
TO THE NEXT LINE.
303
00:17:31,178 --> 00:17:33,704
PREPARED AND WAITING,
304
00:17:33,706 --> 00:17:37,566
THE HATCHBACK BODY SHELL HANGS
IN AN OVERHEAD CAROUSEL BRACKET
305
00:17:37,568 --> 00:17:39,368
BEFORE THE NEXT ASSEMBLY PHASE.
306
00:17:39,370 --> 00:17:42,763
THE DASHBOARD MAY SEEM
UNFAMILIAR,
307
00:17:42,765 --> 00:17:44,099
BUT THIS IS A CRUCIAL STEP
308
00:17:44,101 --> 00:17:46,826
IN INSTALLING
ITS SWITCHES AND DIALS.
309
00:17:48,789 --> 00:17:50,922
IN THE UPHOLSTERY DEPARTMENT,
310
00:17:50,924 --> 00:17:56,387
NEARLY 75% OF ALL INTERIOR
CABIN WORK IS DONE BY HAND.
311
00:17:56,389 --> 00:17:58,914
THE CAR'S CHASSIS IS
ABOUT HIGHER CABIN COMFORT,
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00:17:58,916 --> 00:18:02,275
SPACE REQUIREMENTS,
AND SAFETY STANDARDS.
313
00:18:02,277 --> 00:18:06,005
USING A SPACE-FRAME DESIGN
AND MADE FROM ALUMINUM,
314
00:18:06,007 --> 00:18:07,874
THE CAR'S CHASSIS IS
MUCH LIGHTER
315
00:18:07,876 --> 00:18:10,535
THAN ANY OTHER ROAD CAR
IN THE AUTOMAKER'S HISTORY,
316
00:18:10,537 --> 00:18:14,263
AND WITH GREATER
TORSIONAL RIGIDITY.
317
00:18:14,265 --> 00:18:17,959
THE INTERIORS ARE
ALWAYS PERSONALIZED
318
00:18:17,961 --> 00:18:21,154
WITH OPTIONS LIKE MATCHING
OR CONTRASTING STITCHING,
319
00:18:21,156 --> 00:18:23,223
ACCENTS LIKE CARBON FIBER,
320
00:18:23,225 --> 00:18:26,685
OR FABRICS WITH ALUMINUM EFFECT
OR TITANIUM EFFECT.
321
00:18:26,687 --> 00:18:29,021
WITH THE ASSISTANCE
OF A LIFTING DEVICE,
322
00:18:29,023 --> 00:18:30,881
WORKERS INSTALL THE DASHBOARD,
323
00:18:30,883 --> 00:18:34,110
ENSURING THAT THE CONSOLE PARTS
FIT SECURELY.
324
00:18:34,112 --> 00:18:36,112
ONCE THE DASHBOARD
HAS BEEN MOUNTED,
325
00:18:36,114 --> 00:18:38,973
THE STEERING WHEEL,
EQUIPPED WITH THE MAIN CONTROLS,
326
00:18:38,975 --> 00:18:42,769
WILL BE ADDED, OFFERING
DIFFERENT VEHICLE DYNAMICS.
327
00:18:42,771 --> 00:18:45,631
A WORKER INSPECTS
THE RUNNING GEAR,
328
00:18:45,633 --> 00:18:47,765
WHICH INCLUDES
THE ENGINE AND DRIVETRAIN
329
00:18:47,767 --> 00:18:50,393
FOR INSTALLATION
BELOW THE BODY SHELL.
330
00:18:50,395 --> 00:18:53,797
THIS CAR'S ALL-WHEEL-DRIVE
SYSTEM IS 50% LIGHTER
331
00:18:53,799 --> 00:18:55,190
THAN THE AVERAGE SYSTEM,
332
00:18:55,192 --> 00:18:58,252
WITH TWO INDEPENDENT
TRACTION SYSTEMS.
333
00:18:58,254 --> 00:19:00,988
THE REAR WHEELS PROVIDE
THE POWER,
334
00:19:00,990 --> 00:19:05,118
WITH TORQUE TRANSFERRED ONLY
TO THE FRONT AXLE WHEN REQUIRED.
335
00:19:05,120 --> 00:19:06,844
USING A MECHANIZED DOLLY,
336
00:19:06,846 --> 00:19:09,981
THE WORKER MOVES THE RUNNING
PARTS BELOW THE FRAME,
337
00:19:09,983 --> 00:19:13,009
WHERE ANOTHER WORKER LOWERS
THE CAROUSEL BRACKET,
338
00:19:13,011 --> 00:19:16,605
AND THE LARGE COMPONENTS
MEET HALFWAY.
339
00:19:16,607 --> 00:19:19,733
A TEAM OF WORKERS MERGE
THE RUNNING GEAR,
340
00:19:19,735 --> 00:19:22,661
CONSISTING OF THE SUSPENSION,
STEERING,
341
00:19:22,663 --> 00:19:24,596
AND ALL-WHEEL-DRIVE POWERTRAIN
342
00:19:24,598 --> 00:19:26,757
WITH THE SHOOTING-BRAKE
BODY SHELL,
343
00:19:26,759 --> 00:19:30,461
USING POWER TOOLS
TO LOCK THE PARTS IN PLACE.
344
00:19:35,685 --> 00:19:37,952
WITH THE ASSISTANCE
OF A LIFTING DEVICE,
345
00:19:37,954 --> 00:19:40,813
A WORKER PLACES
THE FIVE-SPOKE RIMS AND TIRES
346
00:19:40,815 --> 00:19:46,478
ON THE RESPECTIVE WHEEL PLATES,
SECURING THEM WITH BOLTS.
347
00:19:48,640 --> 00:19:50,974
BOTH THE FRONT WINDSHIELD
AND REAR WINDOWS
348
00:19:50,976 --> 00:19:52,635
RECEIVE A HIGH-STRENGTH ADHESIVE
349
00:19:52,637 --> 00:19:56,631
THAT A ROBOT DEPOSITS
ONTO THE EDGES OF THE GLASS.
350
00:19:56,633 --> 00:20:01,026
ANOTHER ROBOT PRECISELY
ANTICIPATES THE CAR'S LOCATION
351
00:20:01,028 --> 00:20:04,856
AND DELIVERS THE NEW WINDOWS
INTO THEIR RESPECTIVE POSITIONS
352
00:20:04,858 --> 00:20:08,051
WITH CALCULATED PRESSURE
AND CARE.
353
00:20:13,383 --> 00:20:15,316
AFTER ONE MONTH OF ASSEMBLY,
354
00:20:15,318 --> 00:20:18,212
A WORKER FILLS GASOLINE
INTO THE TANK.
355
00:20:18,214 --> 00:20:21,339
WITH THE MAJORITY
OF THE VITAL PARTS IN PLACE,
356
00:20:21,341 --> 00:20:23,342
THE CAR REQUIRES
A FEW MORE ELEMENTS
357
00:20:23,344 --> 00:20:28,131
BEFORE BECOMING
AN EXTREME TWO-DOOR HATCHBACK.
358
00:20:28,133 --> 00:20:30,466
ALL STYLE AND SOUL ASIDE,
359
00:20:30,468 --> 00:20:33,828
THIS CAR WAS BUILT TO TACKLE
EVEN THE LOWEST-GRIP TERRAIN,
360
00:20:33,830 --> 00:20:37,623
INCLUDING SNOW, ICE, AND DIRT.
361
00:20:37,625 --> 00:20:41,353
ITS MODERN SHOOTING-BRAKE SHAPE
AND STYLING CUES
362
00:20:41,355 --> 00:20:42,887
ARE TO BE ADMIRED.
363
00:20:42,889 --> 00:20:46,750
THE CHASSIS ENGINEERING DELIVERS
SUPER-CAR DYNAMICS
364
00:20:46,752 --> 00:20:49,978
AND THE PRANCING HORSE'S
F1 RACING DNA.
365
00:20:49,980 --> 00:20:51,447
TAILORED TO PERFECTION,
366
00:20:51,449 --> 00:20:54,609
THE LEATHER INTERIOR IS
AS STELLAR AS THE BOLD EXTERIOR.
367
00:20:57,104 --> 00:20:59,839
AS THE FIRST FERRARI
WITH ALL-WHEEL-DRIVE,
368
00:20:59,841 --> 00:21:02,366
THE FF IS STRIKING
WHEN ON THE MOVE.
369
00:21:02,368 --> 00:21:07,464
A V-12 ENGINE PRODUCING 660
HORSEPOWER MAKES IT A SUPER CAR
370
00:21:07,466 --> 00:21:10,993
WHERE SPEED AND POWER ARE NEVER
COMPROMISED IN ANY ENVIRONMENT.
371
00:21:10,995 --> 00:21:16,323
REACHING ZERO TO 60 MILES
PER HOUR IN JUST 3.7 SECONDS,
372
00:21:16,325 --> 00:21:19,118
IT EASILY MELDS
EXTREME PERFORMANCE
373
00:21:19,120 --> 00:21:20,853
WITH DAY-TO-DAY VERSATILITY.
374
00:21:20,855 --> 00:21:23,513
A FRESH TAKE
ON THE SPORTY GRAND TOURER,
375
00:21:23,515 --> 00:21:26,809
THE FF WILL ALWAYS BE
A SUPER CAR
376
00:21:26,811 --> 00:21:30,438
DIFFERENT FROM ANY FERRARI
OR OTHER DREAM CAR EVER MADE.
31160
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