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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"
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00:00:03,003 --> 00:00:04,427
THE PORSCHE PANAMERA --
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00:00:04,429 --> 00:00:08,290
A GRAND TOURER THAT DRIVES
LIKE A HIGH-END SPORTS CAR.
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00:00:08,292 --> 00:00:11,227
-- 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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00:00:37,198 --> 00:00:41,459
NEARBY IS A 1975 VERSION
OF THE 911.
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00:00:41,461 --> 00:00:44,662
THE MOBY DICK IS A 1978 RACECAR
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00:00:44,664 --> 00:00:47,557
DESIGNED
TO COMPETE IN U.S. EVENTS.
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00:00:49,386 --> 00:00:51,786
WITH MORE THAN 28,000 VICTORIES,
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00:00:51,788 --> 00:00:55,716
PORSCHE IS ONE OF THE MOST
SUCCESSFUL NAMES IN MOTORSPORT.
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00:00:57,018 --> 00:01:01,279
BUT RACECARS AREN'T KNOWN
FOR BEING COMFORTABLE,
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00:01:01,281 --> 00:01:03,941
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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00:01:07,472 --> 00:01:10,298
IN FACT,
THE PANAMERA'S PERFORMANCE
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00:01:10,300 --> 00:01:13,960
RIVALS THAT OF ITS CELEBRATED
COUNTERPART, THE 911.
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00:01:19,026 --> 00:01:22,819
THE PANAMERA FEATURES
A LIGHTWEIGHT BODY SHELL.
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00:01:22,821 --> 00:01:28,050
MANUFACTURING IT BEGINS
WITH HUGE PRESSING TOOLS.
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00:01:28,052 --> 00:01:33,247
THE PRESS MANUFACTURES THE CAR'S
BODY SIDES IN SIX STEPS.
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00:01:39,238 --> 00:01:40,838
IN A CONTROL STATION,
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00:01:40,840 --> 00:01:44,667
AN OPERATOR
MONITORS AND MANAGES PRODUCTION.
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00:01:44,669 --> 00:01:47,995
A MECHANISM USES SUCTION
TO PICK UP A SHEET OF METAL
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00:01:47,997 --> 00:01:50,532
AND TRANSFER IT
TO THE PRESSING TOOL.
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PRESSING TOOLS HAVE ALREADY
STAMPED OUT THE INITIAL SHAPE
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00:01:57,257 --> 00:01:59,416
AND OPENINGS ON THESE SHEETS.
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00:01:59,418 --> 00:02:02,552
THE NEXT TOOL
SHAPES THE METAL INTO A PANEL.
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00:02:02,554 --> 00:02:06,615
THIS PANEL INCLUDES A PORTION
OF THE ROOF, THE DOOR OPENINGS,
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00:02:06,617 --> 00:02:10,545
AND THE REAR FENDER WITH
AN OPENING FOR THE FUEL CAP.
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00:02:13,075 --> 00:02:17,101
TRANSFER MECHANISMS
USE VACUUM-POWERED SUCTION CUPS
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00:02:17,103 --> 00:02:20,230
TO QUICKLY MOVE THE PANEL
FROM ONE STATION TO ANOTHER.
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00:02:20,232 --> 00:02:22,499
PRESSING TOOLS
COMPLETE ITS FORMATION
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00:02:22,501 --> 00:02:26,662
IN A HIGHLY EFFICIENT, FULLY
AUTOMATED STAMPING PROCESS.
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00:02:33,421 --> 00:02:35,554
THE FINISHED PANELS
EXIT THE PRESS
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00:02:35,556 --> 00:02:39,450
AND ENTER
A QUALITY-CONTROL AREA.
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00:02:39,452 --> 00:02:40,843
TRAINED INSPECTORS
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00:02:40,845 --> 00:02:44,973
EXAMINE THEIR SURFACES
VISUALLY AND MANUALLY.
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00:02:44,975 --> 00:02:47,309
PORSCHE BUILDS THE LIGHTWEIGHT
BODY SHELL
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00:02:47,311 --> 00:02:48,902
USING A VARIETY OF METALS,
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00:02:48,904 --> 00:02:50,904
INCLUDING HIGH-STRENGTH STEELS,
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00:02:50,906 --> 00:02:54,466
STAINLESS STEEL, MAGNESIUM,
AND ALUMINUM.
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00:02:54,468 --> 00:02:57,594
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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00:03:05,522 --> 00:03:09,082
TO THE FLOOR PLATE AND INNER
PANEL OF THE FRAMEWORK.
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00:03:09,084 --> 00:03:13,745
THIS STEP COMPLETES
THE DOOR-OPENING STRUCTURES.
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00:03:17,342 --> 00:03:20,736
ROBOTS USE SPECIALIZED FIXTURES
TO ALIGN, MOUNT,
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00:03:20,738 --> 00:03:24,739
AND ATTACH THE PANAMERA'S
LIGHTWEIGHT ALUMINUM REAR DOORS.
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00:03:24,741 --> 00:03:27,434
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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00:03:37,688 --> 00:03:40,423
THE INSTALLATION FIXTURES
INCLUDE CAMERAS
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00:03:40,425 --> 00:03:42,584
THAT ENSURE CORRECT ALIGNMENT
OF THE DOORS
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00:03:42,586 --> 00:03:44,719
WITH THEIR OPENINGS.
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00:03:44,721 --> 00:03:47,647
CUSTOMERS CAN OPT
FOR A SOFT-CLOSE SYSTEM,
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00:03:47,649 --> 00:03:49,708
WHICH USES
A SMALL ELECTRIC MOTOR
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00:03:49,710 --> 00:03:52,244
TO SHUT THE DOORS
GENTLY BUT FIRMLY
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00:03:52,246 --> 00:03:55,973
REGARDLESS OF HOW MUCH
OR HOW LITTLE FORCE IS USED.
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00:03:59,537 --> 00:04:03,531
AS THE CAR BODY ADVANCES
ALONG THE PRODUCTION LINE,
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00:04:03,533 --> 00:04:07,126
WORKERS MOUNT FIXTURES
ON THE BODY SHELL.
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00:04:07,128 --> 00:04:10,255
THE PANAMERA IS EQUIPPED
WITH AN ACTIVE HOOD SYSTEM
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00:04:10,257 --> 00:04:13,457
DESIGNED TO HELP
IMPROVE PEDESTRIAN SAFETY.
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00:04:13,459 --> 00:04:16,820
IF THE CAR'S FRONT SENSORS
DETECT A COLLISION, THE SYSTEM
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00:04:16,822 --> 00:04:20,849
INSTANTLY RAISES THE REAR
OF THE HOOD TO REDUCE INJURY.
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00:04:41,631 --> 00:04:45,125
THEY PAINT THE ASSEMBLED BODY
IN FIVE STAGES.
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00:04:55,647 --> 00:04:58,714
FIRST, THE CAR BODY
IS COATED WITH A PHOSPHATE
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00:04:58,716 --> 00:05:01,976
FOR IMPROVED ADHESION.
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00:05:01,978 --> 00:05:05,037
THEY ALSO USE
AN ELECTROPHORETIC COATING,
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00:05:05,039 --> 00:05:07,173
SEAM SEALING,
AND FILLER COATING.
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00:05:07,175 --> 00:05:10,401
DURING THE FINAL STEP,
ROBOTS COAT THE METAL SHELL
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00:05:10,403 --> 00:05:12,862
WITH ITS COLORED BASE COAT
AND CLEAR COAT.
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00:05:12,864 --> 00:05:17,192
THEN THE SHELL IS SENT THROUGH
AN ENORMOUS DRYING OVEN.
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00:05:17,194 --> 00:05:19,194
AFTER THE TOP COAT DRIES,
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THE BODY ARRIVES AT A SPECIALLY
DESIGNED LIGHT TUNNEL.
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00:05:22,457 --> 00:05:25,484
THE LIGHT TUNNEL IS EQUIPPED
WITH L.E.D. TUBES
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00:05:25,486 --> 00:05:27,812
POSITIONED TO CREATE
A UNIFORM LIGHT STRIP PATTERN
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00:05:27,814 --> 00:05:30,147
ON THE SURFACE OF THE CAR BODY.
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00:05:30,149 --> 00:05:33,476
THIS MAKES IT EASIER FOR A TEAM
OF QUALITY-CONTROL INSPECTORS
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00:05:33,478 --> 00:05:36,671
TO DETECT THE TINIEST FLAWS
IN THE PAINT JOB.
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00:05:40,769 --> 00:05:43,903
IF THEY FIND
EVEN THE SLIGHTEST IMPERFECTION,
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00:05:43,905 --> 00:05:46,698
THE INSPECTORS REMOVE THE BODY
FROM THE LINE
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00:05:46,700 --> 00:05:50,361
AND SEND IT FOR SPOT REPAIR.
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THE INSPECTORS ARE SATISFIED
WITH THE PAINT JOB,
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00:05:53,424 --> 00:05:57,318
SO THE CAR BODY IS READY TO HEAD
TO THE ASSEMBLY LINE.
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00:06:10,324 --> 00:06:11,983
Narrator:
THE PORSCHE PANAMERA
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00:06:11,985 --> 00:06:15,052
COMES IN MANY DIFFERENT
POWER TRAIN CONFIGURATIONS,
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00:06:15,054 --> 00:06:17,980
WITH THE PANAMERA S FEATURING
A BURLY 3-LITER,
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00:06:17,982 --> 00:06:20,542
TWIN TURBOCHARGED V-6.
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00:06:22,746 --> 00:06:24,871
A TECHNICIAN PLACES
CONNECTING RODS
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00:06:24,873 --> 00:06:29,734
IN A MACHINE TO CLEAN OFF
ANY STRAY PARTICLES.
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00:06:29,736 --> 00:06:33,531
HE SCANS THE CONRODS, CONFIRMING
THEY'RE THE RIGHT COMPONENTS
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00:06:33,533 --> 00:06:36,425
FOR THE ENGINE HE'S BUILDING.
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00:06:36,427 --> 00:06:40,421
NEXT HE UNSCREWS THE CAPS
AND INSTALLS THE BEARINGS.
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00:06:40,423 --> 00:06:44,417
THE OUTSIDE SURFACE OF EACH
BEARING HAS A TINY NOSE ON IT.
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00:06:44,419 --> 00:06:48,087
THIS FITS PRECISELY INTO A SMALL
NOTCH IN THE CONNECTING ROD,
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00:06:48,089 --> 00:06:50,414
ENSURING THE TECHNICIAN
INSTALLS THE RIGHT BEARING
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00:06:50,416 --> 00:06:52,417
IN THE RIGHT CONROD.
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00:06:54,246 --> 00:06:57,572
HE ASSEMBLES THE CONROD
TO THE PISTONHEAD
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00:06:57,574 --> 00:06:59,641
WITH A PURPOSE-BUILT MACHINE.
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00:06:59,643 --> 00:07:01,969
THE MACHINE
SCANS THE CONNECTING ROD
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00:07:01,971 --> 00:07:05,932
FROM ABOVE TO VERIFY ONCE AGAIN
THAT IT'S THE RIGHT PART.
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00:07:09,195 --> 00:07:10,795
HE PLACES THE PISTONHEAD
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00:07:10,797 --> 00:07:14,990
IN A VISE DESIGNED
TO COMPRESS THE RINGS.
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00:07:14,992 --> 00:07:16,992
A LIFT ASSIST
HELPS THE TECHNICIAN
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00:07:16,994 --> 00:07:18,986
BRING THE CRANKSHAFT
TO THE ENGINE BLOCK
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00:07:18,988 --> 00:07:21,156
AND LOWER IT IN PLACE.
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00:07:24,253 --> 00:07:27,312
HE ROTATES THE BLOCK
ON ITS ASSEMBLY FIXTURE
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00:07:27,314 --> 00:07:30,441
TO GAIN ACCESS TO THE PISTON
BORE HOLES.
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00:07:33,345 --> 00:07:36,204
HE CAREFULLY INSTALLS
SIX PISTONS IN THEIR BORES
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ONE BY ONE.
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00:07:42,064 --> 00:07:43,329
ONCE THEY'RE IN PLACE,
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HE TURNS THE BLOCK AGAIN
TO INSTALL THE CONROD CAPS
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00:07:46,960 --> 00:07:49,987
USING A TORQUING DEVICE
TO TIGHTEN THEM.
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00:07:52,223 --> 00:07:54,749
HE MANUALLY ROTATES
THE CRANKSHAFT TO MAKE SURE
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00:07:54,751 --> 00:07:58,086
THE PISTONS MOVE SMOOTHLY.
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00:07:58,088 --> 00:08:00,213
A FULLY AUTOMATED STATION BRINGS
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00:08:00,215 --> 00:08:03,041
THE UPPER AND LOWER SECTIONS
OF THE ENGINE BLOCK TOGETHER
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00:08:03,043 --> 00:08:05,444
AND BOLTS THEM SECURELY.
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00:08:05,446 --> 00:08:08,973
THE BOLTING PROCESS
IS PERFECTLY SYNCHRONIZED
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00:08:08,975 --> 00:08:11,967
TO MAKE THE BEST CONNECTION
POSSIBLE.
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00:08:11,969 --> 00:08:13,969
PORSCHE HAS DESIGNED
FAIL-SAFE FEATURES
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00:08:13,971 --> 00:08:19,392
INTO THE MANUFACTURING PROCESS
TO PREVENT ASSEMBLY ERRORS.
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00:08:19,394 --> 00:08:21,261
GUIDE PINS ON A LIFT ASSIST
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00:08:21,263 --> 00:08:24,189
HELP THE OPERATOR
POSITION THE CYLINDER HEAD.
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00:08:26,060 --> 00:08:28,518
A TECHNICIAN DROPS
THE CYLINDER HEAD BOLTS
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00:08:28,520 --> 00:08:31,247
INTO THEIR POSITIONS
BEFORE TORQUING THEM DOWN
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00:08:31,249 --> 00:08:33,216
ONE BY ONE.
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00:08:35,745 --> 00:08:38,545
HE GREASES THE CYLINDER HEADS
TO PREPARE THEM
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00:08:38,547 --> 00:08:41,941
FOR THE CAMSHAFT INSTALLATION.
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00:08:41,943 --> 00:08:44,603
THE TECHNICIAN CAREFULLY PLACES
THE CAMSHAFTS
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00:08:44,605 --> 00:08:46,137
OVER THE CYLINDER HEADS.
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00:08:46,139 --> 00:08:49,733
HE LOCKS IT IN PLACE
WITH A JIG, THEN BOLTS IT DOWN.
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00:08:53,497 --> 00:08:56,824
A WORKER POSITIONS
THE PANAMERA'S TIMING CHAIN,
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00:08:56,826 --> 00:09:01,754
CAREFULLY THREADING IT
ONTO THE CAMSHAFT ADJUSTERS.
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00:09:01,756 --> 00:09:05,616
THE CHAINS OPTIMIZE THE TIMING
FOR DIFFERENT LOADS,
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00:09:05,618 --> 00:09:07,844
ENSURING THE ROTATION
OF THE CRANKSHAFT
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00:09:07,846 --> 00:09:11,514
AND THE CAMSHAFT
ARE PERFECTLY SYNCHRONIZED.
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00:09:16,905 --> 00:09:19,506
THE TIMING CASE IS MADE
OF MAGNESIUM,
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00:09:19,508 --> 00:09:22,234
WHICH IS 33% LIGHTER
THAN ALUMINUM
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00:09:22,236 --> 00:09:26,063
AND 75% LIGHTER THAN STEEL.
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00:09:26,065 --> 00:09:28,198
A TECHNICIAN
FINISHES THE OPERATION
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00:09:28,200 --> 00:09:32,387
BY INSTALLING THE CYLINDER
HEAD COVER AND IGNITION COILS.
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00:09:36,451 --> 00:09:39,318
THE V-6 ENGINE
OF THE PORSCHE PANAMERA S
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00:09:39,320 --> 00:09:42,380
IS NEARLY DONE.
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00:09:42,382 --> 00:09:46,009
A WORKER CAREFULLY PLACES
THE COMPOSITE INTAKE MANIFOLD
149
00:09:46,011 --> 00:09:47,411
INTO POSITION.
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00:09:47,413 --> 00:09:50,139
HE USES A TORQUE-CONTROLLED
BOLTING DEVICE
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00:09:50,141 --> 00:09:54,201
TO RUN DOWN THE SCREWS
AND BOLT IT SECURELY IN PLACE.
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00:09:58,132 --> 00:10:01,558
THE COMPLETED V-6
CAN TAKE THE PANAMERA S
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00:10:01,560 --> 00:10:04,829
FROM ZERO TO 60
IN JUST 5.1 SECONDS,
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00:10:04,831 --> 00:10:09,092
WITH A TOP SPEED
OF ALMOST 180 MILES PER HOUR.
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00:10:14,283 --> 00:10:17,150
THE ENGINE JOINS THE REST
OF THE POWER TRAIN
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00:10:17,152 --> 00:10:20,179
ON A YELLOW SUBASSEMBLY WAGON.
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00:10:20,181 --> 00:10:21,839
AS THE WAGON MOVES ON ITS TRACK,
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00:10:21,841 --> 00:10:24,174
MEMBERS
OF THE PORSCHE PRODUCTION TEAM
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00:10:24,176 --> 00:10:26,002
COMPLETE THE ASSEMBLY.
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00:10:28,238 --> 00:10:30,698
A TECHNICIAN
USES A TORQUE-CONTROLLED DRIVER
161
00:10:30,700 --> 00:10:31,965
TO RUN DOWN THE BOLTS
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00:10:31,967 --> 00:10:35,328
THAT ATTACH THE PROP SHAFT
TO THE TRANSMISSION.
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00:10:35,330 --> 00:10:39,857
THE SHAFT CAN NOW TRANSFER POWER
TO THE REAR AXLE.
164
00:10:39,859 --> 00:10:41,659
MADE OF STAINLESS STEEL,
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00:10:41,661 --> 00:10:43,920
THE EXHAUST
IS A LIGHTWEIGHT SYSTEM,
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00:10:43,922 --> 00:10:46,915
FEATURING CATALYTIC CONVERTERS
THAT HEAT UP RAPIDLY
167
00:10:46,917 --> 00:10:49,251
FOR INCREASED EMISSIONS CONTROL.
168
00:10:49,253 --> 00:10:54,014
INTERNAL DESIGN FEATURES
ENHANCE SOUND AT HIGH REVS.
169
00:10:54,016 --> 00:10:56,008
VARIABLE CAMSHAFT CONTROL,
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00:10:56,010 --> 00:10:58,736
TURBO CHARGING, RECUPERATION,
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00:10:58,738 --> 00:11:00,271
AUTO START-STOP,
172
00:11:00,273 --> 00:11:02,206
AND A COASTING FUNCTION
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00:11:02,208 --> 00:11:04,934
ALL COMBINE
TO MAKE THIS V-6 MORE EFFICIENT
174
00:11:04,936 --> 00:11:07,629
AND MORE POWERFUL
THAN ITS PREDECESSOR.
175
00:11:15,784 --> 00:11:17,784
Narrator:
THE PANAMERA'S PERFORMANCE
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00:11:17,786 --> 00:11:20,578
RECALLS THE SPORTS CAR POWER
AND AGILITY
177
00:11:20,580 --> 00:11:22,513
THAT MADE PORSCHE FAMOUS,
178
00:11:22,515 --> 00:11:26,777
BUT THE INTERIOR IS THAT
OF A PLUSH AND ROOMY SEDAN.
179
00:11:28,339 --> 00:11:31,332
BUYERS CAN CUSTOMIZE EVERYTHING
FROM THE DASHBOARD
180
00:11:31,334 --> 00:11:33,367
TO THE SEAT COVERS.
181
00:11:35,996 --> 00:11:38,530
PANAMERA CAR BODIES
TAKE THE TRAIN
182
00:11:38,532 --> 00:11:40,492
FROM THE PORSCHE FACILITY
IN HANOVER
183
00:11:40,494 --> 00:11:42,760
TO THIS PLANT IN LEIPZIG.
184
00:11:42,762 --> 00:11:47,949
FIRST, THEY ORGANIZE THE CARS
IN AN OPTIMAL SEQUENCE.
185
00:11:47,951 --> 00:11:52,946
THEN THE CAR BODIES DESCEND
TO THE MAIN ASSEMBLY AREA.
186
00:11:52,948 --> 00:11:55,015
WITH THE HELP OF A LIFT ASSIST,
187
00:11:55,017 --> 00:11:58,844
IT TAKES JUST 2 1/2 MINUTES
TO INSTALL THE DASHBOARD.
188
00:11:58,846 --> 00:12:01,372
SINCE EACH PANAMERA
IS CUSTOM-MADE,
189
00:12:01,374 --> 00:12:03,875
EACH DASHBOARD IS UNIQUE.
190
00:12:06,972 --> 00:12:10,164
BUILT BY A NEARBY SUPPLIER,
191
00:12:10,166 --> 00:12:14,661
THE DASHBOARDS COME
WITH THE WIRING HARNESS.
192
00:12:14,663 --> 00:12:17,122
THE HARNESS IS UNIQUE
TO THE CAR, TOO.
193
00:12:17,124 --> 00:12:18,790
THE NUMBER OF CONNECTIONS
DEPENDS
194
00:12:18,792 --> 00:12:22,386
ON THE CUSTOMER'S
SPECIFIC REQUIREMENTS.
195
00:12:22,388 --> 00:12:25,514
WHEN THE COMPUTER PROGRAM
RESPONSIBLE FOR SEQUENCING
196
00:12:25,516 --> 00:12:28,050
THE CARS CALCULATES THE ORDER
OF PRODUCTION,
197
00:12:28,052 --> 00:12:33,072
IT FACTORS IN THE AVAILABILITY
OF THE PARTS REQUIRED.
198
00:12:33,074 --> 00:12:35,608
IT ALSO CONSIDERS
THE ASSEMBLY TEAM'S NEED
199
00:12:35,610 --> 00:12:37,602
FOR VARIETY.
200
00:12:37,604 --> 00:12:40,604
THE TEAM CONSISTS
OF HIGHLY TRAINED TECHNICIANS,
201
00:12:40,606 --> 00:12:43,199
CAPABLE OF PERFORMING
MULTIPLE TASKS.
202
00:12:43,201 --> 00:12:45,894
PROGRAMMING VARIETY
INTO THE PRODUCTION LINE
203
00:12:45,896 --> 00:12:48,497
PROMOTES
HIGH-QUALITY WORKMANSHIP.
204
00:12:54,421 --> 00:12:57,547
A ROBOT USES
VACUUM-POWERED SUCTION CUPS
205
00:12:57,549 --> 00:12:59,617
TO HOLD A WINDSHIELD IN PLACE
206
00:12:59,619 --> 00:13:03,346
AS A BEAD OF SEALANT
IS APPLIED AROUND THE PERIMETER.
207
00:13:05,842 --> 00:13:09,970
CUSTOMERS CAN OPT FOR THERMALLY
AND NOISE-INSULATED GLASS,
208
00:13:09,972 --> 00:13:13,273
AS WELL AS DARK TINTING
TO ENHANCE PRIVACY.
209
00:13:15,970 --> 00:13:20,130
THE ROBOT CAREFULLY POSITIONS
THE GLASS ON A TABLE,
210
00:13:20,132 --> 00:13:24,360
ENSURING THAT IT'S IN PRECISELY
THE RIGHT SPOT FOR INSTALLATION.
211
00:13:28,791 --> 00:13:30,650
WITH THE SEALANT APPLIED
212
00:13:30,652 --> 00:13:33,585
AND THE WINDSHIELD PERFECTLY
CENTERED ON ITS FIXTURE,
213
00:13:33,587 --> 00:13:37,315
THE ROBOT CAN QUICKLY
INSTALL THE GLASS IN ITS FRAME.
214
00:13:40,012 --> 00:13:41,877
A PORSCHE ASSEMBLY TEAM MEMBER
215
00:13:41,879 --> 00:13:44,806
BRINGS THE REAR CENTER
CONSOLE COVER INTO THE CAR
216
00:13:44,808 --> 00:13:49,002
AND USES A DRIVER TO INSTALL IT.
217
00:13:49,004 --> 00:13:53,866
INSTALLATION OF THE CONSOLES
CAN TAKE UP TO 9 MINUTES.
218
00:13:53,868 --> 00:13:58,562
THIS OF COURSE DEPENDS ON THE
OPTIONS CHOSEN BY THE CUSTOMER.
219
00:13:58,564 --> 00:14:02,817
HERE, THE TECHNICIAN INSTALLS
THE CONSOLE'S FRONT SECTION.
220
00:14:02,819 --> 00:14:06,153
IT INCLUDES THE CONTROL PANEL
FOR THE AIR CONDITIONER
221
00:14:06,155 --> 00:14:08,481
AND THE COVER
OF THE GEAR SHIFT MODULE,
222
00:14:08,483 --> 00:14:10,149
WHICH HOUSES MULTIPLE CONTROLS
223
00:14:10,151 --> 00:14:13,478
ON EITHER SIDE
OF THE STICK SHIFTER.
224
00:14:22,706 --> 00:14:25,966
HERE, TECHNICIANS
INSTALL THE FRONT SEATS.
225
00:14:25,968 --> 00:14:29,529
PORSCHE PRACTICES
MODEL-MIXED PRODUCTION.
226
00:14:29,531 --> 00:14:32,056
THIS MEANS CARS
WITH A HIGH NUMBER OF OPTIONS
227
00:14:32,058 --> 00:14:36,852
ARE INTERSPERSED
WITH LOW-OPTION VERSIONS.
228
00:14:36,854 --> 00:14:39,915
MIXED PRODUCTION
HELPS KEEP PRODUCTION TIME
229
00:14:39,917 --> 00:14:41,516
AT A CONSTANT RATE,
230
00:14:41,518 --> 00:14:45,913
REGARDLESS OF THE COMPLEXITY
OF A PARTICULAR ASSEMBLY.
231
00:14:47,349 --> 00:14:50,342
TEAM MEMBERS
INSTALL THE FRONT-END MODULE.
232
00:14:50,344 --> 00:14:54,672
THIS MODULE CONTAINS THE CAR'S
COMPLETE COOLING PACKAGE.
233
00:14:54,674 --> 00:14:57,199
THEY FASTEN IT IN TWO STAGES --
234
00:14:57,201 --> 00:14:59,401
FIRST
WITH BATTERY-POWERED DRIVERS
235
00:14:59,403 --> 00:15:02,564
AND THEN WITH
A TORQUE-CONTROLLED TIGHTENER.
236
00:15:04,893 --> 00:15:07,493
NEXT,
THEY ADD THE LIGHTWEIGHT BUMPER,
237
00:15:07,495 --> 00:15:10,622
WHICH HELPS TO DEFINE
THE SIGNATURE SLEEK PORSCHE LOOK
238
00:15:10,624 --> 00:15:13,917
WITH ITS SLOPING NOSE
AND LONG-SLUNG GRILLE.
239
00:15:15,888 --> 00:15:17,913
A TECHNICIAN
FITS THE HEADLIGHTS
240
00:15:17,915 --> 00:15:19,981
SNUGLY INTO THEIR APERTURES.
241
00:15:19,983 --> 00:15:22,710
THEY'RE SHAPED LIKE
UPSIDE-DOWN TEARDROPS.
242
00:15:22,712 --> 00:15:26,339
SPECIALISTS WILL LATER TUNE
THEIR HEIGHT AND DIRECTION.
243
00:15:27,909 --> 00:15:29,433
A WORKER USES A TOOL
244
00:15:29,435 --> 00:15:32,036
TO CHECK THE GAPS
BETWEEN THE HOOD, THE BUMPER,
245
00:15:32,038 --> 00:15:34,664
AND THE FENDERS.
246
00:15:34,666 --> 00:15:39,328
THE CARS MOVE ON PLATFORMS
EQUIPPED WITH WOOD FLOORING.
247
00:15:39,330 --> 00:15:42,388
WOOD FLOORING IS MORE
ERGONOMICALLY COMFORTABLE
248
00:15:42,390 --> 00:15:43,857
FOR THE ASSEMBLY TEAM MEMBERS
249
00:15:43,859 --> 00:15:46,919
TO WORK ON
THAN CONCRETE OR STEEL.
250
00:15:46,921 --> 00:15:48,854
FOR ADDITIONAL
ERGONOMIC COMFORT,
251
00:15:48,856 --> 00:15:52,717
A TECHNICIAN USES A LIFT
ASSIST TO INSTALL A DOOR.
252
00:15:54,679 --> 00:15:56,412
THE UNDERSIDE OF THE CAR BODY
253
00:15:56,414 --> 00:15:59,073
HAS BEEN LEFT
OPEN TO ALLOW FOR ITS MARRIAGE
254
00:15:59,075 --> 00:16:00,875
WITH THE POWER TRAIN.
255
00:16:00,877 --> 00:16:04,604
THE POWER TRAIN SLIDES LATERALLY
INTO POSITION ON ITS FIXTURE
256
00:16:04,606 --> 00:16:09,333
AS AN OVERHEAD CARRIER
BRINGS THE BODY OVER IT.
257
00:16:09,335 --> 00:16:11,695
THEN THE POWER TRAIN ASCENDS.
258
00:16:11,697 --> 00:16:15,023
AT THIS FACILITY, THE MARRIAGE
IS ENTIRELY AUTOMATED
259
00:16:15,025 --> 00:16:17,660
AND TAKES JUST 2 MINUTES
TO COMPLETE.
260
00:16:24,285 --> 00:16:27,779
A TECHNICIAN INSTALLS
THE DRIVER-SIDE FRONT AIR BAG
261
00:16:27,781 --> 00:16:29,847
IN THE STEERING WHEEL.
262
00:16:29,849 --> 00:16:31,241
FOR MINOR ACCIDENTS,
263
00:16:31,243 --> 00:16:34,936
THE AIR BAGS PARTIALLY INFLATE
TO MINIMIZE DISCOMFORT.
264
00:16:39,702 --> 00:16:42,994
A TEAM MEMBER WORKS
WITH A FULLY AUTOMATED MECHANISM
265
00:16:42,996 --> 00:16:47,791
TO BRING A WHEEL
TO THE RIGHT REAR WHEELBASE,
266
00:16:47,793 --> 00:16:51,721
MOUNT IT, AND TORQUE THE LUGS.
267
00:16:51,723 --> 00:16:55,983
THE PANAMERA COMES STANDARD
WITH 18-INCH ALLOY WHEELS
268
00:16:55,985 --> 00:16:59,212
AND THE PORSCHE ACTIVE
SUSPENSION MANAGEMENT SYSTEM,
269
00:16:59,214 --> 00:17:01,014
WHICH ADJUSTS THE DAMPING FORCE
270
00:17:01,016 --> 00:17:04,776
ON EACH WHEEL
ACCORDING TO ROAD CONDITIONS.
271
00:17:10,671 --> 00:17:13,664
Narrator: IT'S HARD TO BELIEVE
THAT PORSCHE WAS NEARLY BANKRUPT
272
00:17:13,666 --> 00:17:15,399
IN THE EARLY 1990s.
273
00:17:15,401 --> 00:17:18,861
THE COMPANY TURNED ITSELF AROUND
SO COMPLETELY THAT IT NOW
274
00:17:18,863 --> 00:17:22,523
MAKES MORE MONEY PER CAR
THAN ANY OTHER MANUFACTURER.
275
00:17:22,525 --> 00:17:24,058
THE TURNAROUND BEGAN
WHEN PORSCHE
276
00:17:24,060 --> 00:17:27,654
INTRODUCED LEAN MANUFACTURING
PRINCIPLES FROM JAPAN.
277
00:17:29,783 --> 00:17:33,810
FAMED LEAN MANUFACTURING
CONSULTANT W. EDWARDS DEMING
278
00:17:33,812 --> 00:17:38,741
WROTE, "YOU CAN'T INSPECT
QUALITY INTO A PRODUCT."
279
00:17:38,743 --> 00:17:42,536
IN OTHER WORDS, THE QUALITY
IS EITHER THERE, OR IT'S NOT.
280
00:17:42,538 --> 00:17:46,532
NEVERTHELESS, QUALITY CONTROL
IS A CRUCIALLY IMPORTANT STEP
281
00:17:46,534 --> 00:17:47,934
IN PRODUCTION.
282
00:17:47,936 --> 00:17:49,827
A HIGHLY TRAINED INSPECTOR
283
00:17:49,829 --> 00:17:53,556
SCRUTINIZES EVERY ASPECT
OF THE CAR INSIDE AND OUT,
284
00:17:53,558 --> 00:17:57,352
NOTING AND RECORDING ANY FLAWS.
285
00:17:57,354 --> 00:18:00,889
BEFORE STARTING, INSPECTORS
MUST REMOVE ANY BELTS,
286
00:18:00,891 --> 00:18:05,151
WATCHES, OR OTHER METAL
THAT COULD SCRATCH THE PAINT.
287
00:18:05,153 --> 00:18:07,979
WITH THE FIT
AND FINISH FULLY INSPECTED,
288
00:18:07,981 --> 00:18:12,376
THIS CAR
IS READY FOR FURTHER TESTING.
289
00:18:12,378 --> 00:18:15,637
A DRIVER STARTS UP THE CAR
FOR THE FIRST TIME.
290
00:18:15,639 --> 00:18:17,832
HE GUIDES IT
TO A ROLLING ROAD STATION
291
00:18:17,834 --> 00:18:20,401
IN THE DYNAMIC TESTING AREA.
292
00:18:22,130 --> 00:18:25,265
THE DRIVER FOLLOWS THE
DIRECTIONS OF A COMPUTER PROGRAM
293
00:18:25,267 --> 00:18:26,791
AND RUNS THE CAR
294
00:18:26,793 --> 00:18:29,427
THROUGH A BATTERY
OF DIFFERENT DRIVING MODES.
295
00:18:35,385 --> 00:18:37,519
THE PANAMERA ENTERS A BOOTH,
296
00:18:37,521 --> 00:18:39,213
WHERE HIGH-PRESSURE WATER JETS
297
00:18:39,215 --> 00:18:42,015
SIMULATE MONSOON CONDITIONS.
298
00:18:42,017 --> 00:18:43,942
NOZZLES POSITIONED ABOVE,
299
00:18:43,944 --> 00:18:46,370
BELOW, AND ON BOTH SIDES
OF THE CAR
300
00:18:46,372 --> 00:18:50,800
SHOOT SEVERAL HUNDRED GALLONS
OF WATER PER MINUTE.
301
00:18:50,802 --> 00:18:53,903
THE INTERIOR OF THE CAR
MUST BE COMPLETELY DRY,
302
00:18:53,905 --> 00:18:55,931
OR IT DOESN'T PASS THE TEST.
303
00:18:58,569 --> 00:19:01,762
AFTER LEAVING THE LEAKAGE
TEST BOOTH, THE DRIVER
304
00:19:01,764 --> 00:19:05,357
STEERS THE PANAMERA TO THE FINAL
STATIC CONTROL GATE,
305
00:19:05,359 --> 00:19:08,452
ALSO KNOWN
AS QUALITY GATE EIGHT.
306
00:19:10,222 --> 00:19:13,850
OUTSIDE, A DRIVER TAKES THE CAR
OVER A COBBLESTONE STRIP
307
00:19:13,852 --> 00:19:16,344
TO GAUGE INTERIOR NOISE.
308
00:19:17,847 --> 00:19:20,706
LEATHER UPHOLSTERY
TENDS TO BE SQUEAKY,
309
00:19:20,708 --> 00:19:23,668
BUT PORSCHE STRIVES
TO MINIMIZE THIS.
310
00:19:25,838 --> 00:19:28,265
THE TEST DRIVER
THEN STEERS THE PANAMERA
311
00:19:28,267 --> 00:19:31,201
UP THE SLOPE
OF A PURPOSE-BUILT TESTING HILL
312
00:19:31,203 --> 00:19:32,994
AND STOPS IT ON THE INCLINE
313
00:19:32,996 --> 00:19:36,323
TO CHECK THE HILL-HOLD FUNCTION
OF THE BRAKES.
314
00:19:39,554 --> 00:19:41,587
THEN HE TAKES IT OVER THE TOP
315
00:19:41,589 --> 00:19:45,383
AND TESTS THE CAR
ON THE DOWNWARD SLOPE.
316
00:19:45,385 --> 00:19:46,918
THE PANAMERA COMES STANDARD
317
00:19:46,920 --> 00:19:49,278
WITH THE PORSCHE TRACTION
MANAGEMENT SYSTEM,
318
00:19:49,280 --> 00:19:51,873
WHICH INCLUDES AUTOMATIC BRAKE
DIFFERENTIAL
319
00:19:51,875 --> 00:19:54,009
AND ANTISLIP REGULATION.
320
00:19:56,738 --> 00:19:59,072
IT'S NOW WORTHY OF DISPLAY
AT A VENUE
321
00:19:59,074 --> 00:20:02,267
LIKE THE LEIPZIG PORSCHE
CUSTOMER CARE CENTER.
322
00:20:04,430 --> 00:20:07,565
ONE WAY TO TELL THE DIFFERENT
PANAMERA MODELS APART
323
00:20:07,567 --> 00:20:11,560
IS BY LOOKING AT THE COLOR
OF THEIR BRAKE CALIPERS.
324
00:20:11,562 --> 00:20:13,554
YELLOW BRAKE CALIPERS
325
00:20:13,556 --> 00:20:18,351
SIGNIFY PORSCHE CERAMIC
COMPOSITE BRAKES, OR PCCBs.
326
00:20:18,353 --> 00:20:21,312
WITH ENHANCED PERFORMANCE,
FUEL ECONOMY, AND HANDLING,
327
00:20:21,314 --> 00:20:26,376
PCCBs CAN BE FITTED
ONTO ANY PANAMERA UPON REQUEST,
328
00:20:26,378 --> 00:20:30,505
BUT IT COMES STANDARD
ON THE TURBO S.
329
00:20:30,507 --> 00:20:34,167
WITH ITS 4.8-LITER
TWIN TURBO V-8 POWERHOUSE,
330
00:20:34,169 --> 00:20:36,703
THE TURBO S ACHIEVES
A MAXIMUM TORQUE
331
00:20:36,705 --> 00:20:38,730
OF 516 FOOT-POUNDS
332
00:20:38,732 --> 00:20:42,393
BETWEEN 2,500 AND 5,000 RPMs,
333
00:20:42,395 --> 00:20:46,722
ACCELERATES FROM ZERO TO 60
IN JUST 3.8 SECONDS,
334
00:20:46,724 --> 00:20:52,053
AND REACHES A TOP SPEED
OF 192 MILES PER HOUR.
335
00:20:53,282 --> 00:20:56,816
WHEN PORSCHE
INTRODUCED THE PANAMERA IN 2009,
336
00:20:56,818 --> 00:20:59,211
CAR FANS WERE SKEPTICAL
THAT A COMPANY
337
00:20:59,213 --> 00:21:00,479
FAMOUS FOR MANUFACTURING
338
00:21:00,481 --> 00:21:03,607
SOME OF THE MOST CELEBRATED
SPORTS CARS EVER BUILT
339
00:21:03,609 --> 00:21:07,803
COULD REALLY PULL OFF
A FOUR-DOOR LUXURY GRAND TOURER.
340
00:21:07,805 --> 00:21:11,365
BUT THE PANAMERA
HAS BEEN AN ENORMOUS SUCCESS.
341
00:21:11,367 --> 00:21:13,893
DESPITE FEELING LIKE A SEDAN,
342
00:21:13,895 --> 00:21:15,161
THE PANAMERA STILL
343
00:21:15,163 --> 00:21:18,223
LOOKS AND PERFORMS
LIKE A PORSCHE.
344
00:21:18,225 --> 00:21:19,690
IN OTHER WORDS,
345
00:21:19,692 --> 00:21:22,686
DRIVING A PANAMERA
IS LIKE DRIVING A SPORTS CAR,
346
00:21:22,688 --> 00:21:26,381
EXCEPT IT'S ROOMY, PLUSH,
AND HAS SPACE FOR LUGGAGE.
347
00:21:26,383 --> 00:21:29,584
AND LIKE ALL PORSCHES,
IT'S NOT JUST FAST,
348
00:21:29,586 --> 00:21:31,745
IT'S ALSO RELIABLE.
28201
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