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These are the user uploaded subtitles that are being translated: 1 00:00:01,535 --> 00:00:03,001 Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS," 2 00:00:03,003 --> 00:00:04,427 THE PORSCHE PANAMERA -- 3 00:00:04,429 --> 00:00:08,290 A GRAND TOURER THAT DRIVES LIKE A HIGH-END SPORTS CAR. 4 00:00:08,292 --> 00:00:11,227 -- Captions by VITAC -- www.vitac.com 5 00:00:11,229 --> 00:00:14,255 CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS 6 00:00:23,249 --> 00:00:25,842 AT THE PORSCHE MUSEUM IN STUTTGART, GERMANY, 7 00:00:25,844 --> 00:00:29,772 THE COMPANY'S FAMOUS CAR DESIGNS ARE ON DISPLAY. 8 00:00:29,774 --> 00:00:32,775 IT THE LATE 1940s, THE 356 9 00:00:32,777 --> 00:00:37,196 WAS THE FIRST OFFICIAL SERIAL PRODUCTION CAR MADE BY PORSCHE. 10 00:00:37,198 --> 00:00:41,459 NEARBY IS A 1975 VERSION OF THE 911. 11 00:00:41,461 --> 00:00:44,662 THE MOBY DICK IS A 1978 RACECAR 12 00:00:44,664 --> 00:00:47,557 DESIGNED TO COMPETE IN U.S. EVENTS. 13 00:00:49,386 --> 00:00:51,786 WITH MORE THAN 28,000 VICTORIES, 14 00:00:51,788 --> 00:00:55,716 PORSCHE IS ONE OF THE MOST SUCCESSFUL NAMES IN MOTORSPORT. 15 00:00:57,018 --> 00:01:01,279 BUT RACECARS AREN'T KNOWN FOR BEING COMFORTABLE, 16 00:01:01,281 --> 00:01:03,941 SO PORSCHE CREATED A FOUR-DOOR LUXURY SEDAN 17 00:01:03,943 --> 00:01:07,470 THAT COMBINED POWER AND SPEED WITH COMFORT AND STYLE. 18 00:01:07,472 --> 00:01:10,298 IN FACT, THE PANAMERA'S PERFORMANCE 19 00:01:10,300 --> 00:01:13,960 RIVALS THAT OF ITS CELEBRATED COUNTERPART, THE 911. 20 00:01:19,026 --> 00:01:22,819 THE PANAMERA FEATURES A LIGHTWEIGHT BODY SHELL. 21 00:01:22,821 --> 00:01:28,050 MANUFACTURING IT BEGINS WITH HUGE PRESSING TOOLS. 22 00:01:28,052 --> 00:01:33,247 THE PRESS MANUFACTURES THE CAR'S BODY SIDES IN SIX STEPS. 23 00:01:39,238 --> 00:01:40,838 IN A CONTROL STATION, 24 00:01:40,840 --> 00:01:44,667 AN OPERATOR MONITORS AND MANAGES PRODUCTION. 25 00:01:44,669 --> 00:01:47,995 A MECHANISM USES SUCTION TO PICK UP A SHEET OF METAL 26 00:01:47,997 --> 00:01:50,532 AND TRANSFER IT TO THE PRESSING TOOL. 27 00:01:53,729 --> 00:01:57,255 PRESSING TOOLS HAVE ALREADY STAMPED OUT THE INITIAL SHAPE 28 00:01:57,257 --> 00:01:59,416 AND OPENINGS ON THESE SHEETS. 29 00:01:59,418 --> 00:02:02,552 THE NEXT TOOL SHAPES THE METAL INTO A PANEL. 30 00:02:02,554 --> 00:02:06,615 THIS PANEL INCLUDES A PORTION OF THE ROOF, THE DOOR OPENINGS, 31 00:02:06,617 --> 00:02:10,545 AND THE REAR FENDER WITH AN OPENING FOR THE FUEL CAP. 32 00:02:13,075 --> 00:02:17,101 TRANSFER MECHANISMS USE VACUUM-POWERED SUCTION CUPS 33 00:02:17,103 --> 00:02:20,230 TO QUICKLY MOVE THE PANEL FROM ONE STATION TO ANOTHER. 34 00:02:20,232 --> 00:02:22,499 PRESSING TOOLS COMPLETE ITS FORMATION 35 00:02:22,501 --> 00:02:26,662 IN A HIGHLY EFFICIENT, FULLY AUTOMATED STAMPING PROCESS. 36 00:02:33,421 --> 00:02:35,554 THE FINISHED PANELS EXIT THE PRESS 37 00:02:35,556 --> 00:02:39,450 AND ENTER A QUALITY-CONTROL AREA. 38 00:02:39,452 --> 00:02:40,843 TRAINED INSPECTORS 39 00:02:40,845 --> 00:02:44,973 EXAMINE THEIR SURFACES VISUALLY AND MANUALLY. 40 00:02:44,975 --> 00:02:47,309 PORSCHE BUILDS THE LIGHTWEIGHT BODY SHELL 41 00:02:47,311 --> 00:02:48,902 USING A VARIETY OF METALS, 42 00:02:48,904 --> 00:02:50,904 INCLUDING HIGH-STRENGTH STEELS, 43 00:02:50,906 --> 00:02:54,466 STAINLESS STEEL, MAGNESIUM, AND ALUMINUM. 44 00:02:54,468 --> 00:02:57,594 THIS RESULTS IN A LOW OVERALL WEIGHT. 45 00:02:57,596 --> 00:03:02,057 IT ALSO PRODUCES A SAFE, RESILIENT VEHICLE. 46 00:03:02,059 --> 00:03:05,520 ROBOTS SIMULTANEOUSLY BRING THE LEFT AND RIGHT BODY SIDES 47 00:03:05,522 --> 00:03:09,082 TO THE FLOOR PLATE AND INNER PANEL OF THE FRAMEWORK. 48 00:03:09,084 --> 00:03:13,745 THIS STEP COMPLETES THE DOOR-OPENING STRUCTURES. 49 00:03:17,342 --> 00:03:20,736 ROBOTS USE SPECIALIZED FIXTURES TO ALIGN, MOUNT, 50 00:03:20,738 --> 00:03:24,739 AND ATTACH THE PANAMERA'S LIGHTWEIGHT ALUMINUM REAR DOORS. 51 00:03:24,741 --> 00:03:27,434 THE DOORS COME WITH INTEGRATED SIDE-IMPACT PROTECTION 52 00:03:27,436 --> 00:03:29,395 IN ALL MODELS. 53 00:03:32,300 --> 00:03:34,959 NEXT, ROBOTS TRANSFER THE FRONT DOORS 54 00:03:34,961 --> 00:03:37,686 TO THE BODY SHELL AND INSTALL THEM. 55 00:03:37,688 --> 00:03:40,423 THE INSTALLATION FIXTURES INCLUDE CAMERAS 56 00:03:40,425 --> 00:03:42,584 THAT ENSURE CORRECT ALIGNMENT OF THE DOORS 57 00:03:42,586 --> 00:03:44,719 WITH THEIR OPENINGS. 58 00:03:44,721 --> 00:03:47,647 CUSTOMERS CAN OPT FOR A SOFT-CLOSE SYSTEM, 59 00:03:47,649 --> 00:03:49,708 WHICH USES A SMALL ELECTRIC MOTOR 60 00:03:49,710 --> 00:03:52,244 TO SHUT THE DOORS GENTLY BUT FIRMLY 61 00:03:52,246 --> 00:03:55,973 REGARDLESS OF HOW MUCH OR HOW LITTLE FORCE IS USED. 62 00:03:59,537 --> 00:04:03,531 AS THE CAR BODY ADVANCES ALONG THE PRODUCTION LINE, 63 00:04:03,533 --> 00:04:07,126 WORKERS MOUNT FIXTURES ON THE BODY SHELL. 64 00:04:07,128 --> 00:04:10,255 THE PANAMERA IS EQUIPPED WITH AN ACTIVE HOOD SYSTEM 65 00:04:10,257 --> 00:04:13,457 DESIGNED TO HELP IMPROVE PEDESTRIAN SAFETY. 66 00:04:13,459 --> 00:04:16,820 IF THE CAR'S FRONT SENSORS DETECT A COLLISION, THE SYSTEM 67 00:04:16,822 --> 00:04:20,849 INSTANTLY RAISES THE REAR OF THE HOOD TO REDUCE INJURY. 68 00:04:41,631 --> 00:04:45,125 THEY PAINT THE ASSEMBLED BODY IN FIVE STAGES. 69 00:04:55,647 --> 00:04:58,714 FIRST, THE CAR BODY IS COATED WITH A PHOSPHATE 70 00:04:58,716 --> 00:05:01,976 FOR IMPROVED ADHESION. 71 00:05:01,978 --> 00:05:05,037 THEY ALSO USE AN ELECTROPHORETIC COATING, 72 00:05:05,039 --> 00:05:07,173 SEAM SEALING, AND FILLER COATING. 73 00:05:07,175 --> 00:05:10,401 DURING THE FINAL STEP, ROBOTS COAT THE METAL SHELL 74 00:05:10,403 --> 00:05:12,862 WITH ITS COLORED BASE COAT AND CLEAR COAT. 75 00:05:12,864 --> 00:05:17,192 THEN THE SHELL IS SENT THROUGH AN ENORMOUS DRYING OVEN. 76 00:05:17,194 --> 00:05:19,194 AFTER THE TOP COAT DRIES, 77 00:05:19,196 --> 00:05:22,455 THE BODY ARRIVES AT A SPECIALLY DESIGNED LIGHT TUNNEL. 78 00:05:22,457 --> 00:05:25,484 THE LIGHT TUNNEL IS EQUIPPED WITH L.E.D. TUBES 79 00:05:25,486 --> 00:05:27,812 POSITIONED TO CREATE A UNIFORM LIGHT STRIP PATTERN 80 00:05:27,814 --> 00:05:30,147 ON THE SURFACE OF THE CAR BODY. 81 00:05:30,149 --> 00:05:33,476 THIS MAKES IT EASIER FOR A TEAM OF QUALITY-CONTROL INSPECTORS 82 00:05:33,478 --> 00:05:36,671 TO DETECT THE TINIEST FLAWS IN THE PAINT JOB. 83 00:05:40,769 --> 00:05:43,903 IF THEY FIND EVEN THE SLIGHTEST IMPERFECTION, 84 00:05:43,905 --> 00:05:46,698 THE INSPECTORS REMOVE THE BODY FROM THE LINE 85 00:05:46,700 --> 00:05:50,361 AND SEND IT FOR SPOT REPAIR. 86 00:05:50,363 --> 00:05:53,422 THE INSPECTORS ARE SATISFIED WITH THE PAINT JOB, 87 00:05:53,424 --> 00:05:57,318 SO THE CAR BODY IS READY TO HEAD TO THE ASSEMBLY LINE. 88 00:06:10,324 --> 00:06:11,983 Narrator: THE PORSCHE PANAMERA 89 00:06:11,985 --> 00:06:15,052 COMES IN MANY DIFFERENT POWER TRAIN CONFIGURATIONS, 90 00:06:15,054 --> 00:06:17,980 WITH THE PANAMERA S FEATURING A BURLY 3-LITER, 91 00:06:17,982 --> 00:06:20,542 TWIN TURBOCHARGED V-6. 92 00:06:22,746 --> 00:06:24,871 A TECHNICIAN PLACES CONNECTING RODS 93 00:06:24,873 --> 00:06:29,734 IN A MACHINE TO CLEAN OFF ANY STRAY PARTICLES. 94 00:06:29,736 --> 00:06:33,531 HE SCANS THE CONRODS, CONFIRMING THEY'RE THE RIGHT COMPONENTS 95 00:06:33,533 --> 00:06:36,425 FOR THE ENGINE HE'S BUILDING. 96 00:06:36,427 --> 00:06:40,421 NEXT HE UNSCREWS THE CAPS AND INSTALLS THE BEARINGS. 97 00:06:40,423 --> 00:06:44,417 THE OUTSIDE SURFACE OF EACH BEARING HAS A TINY NOSE ON IT. 98 00:06:44,419 --> 00:06:48,087 THIS FITS PRECISELY INTO A SMALL NOTCH IN THE CONNECTING ROD, 99 00:06:48,089 --> 00:06:50,414 ENSURING THE TECHNICIAN INSTALLS THE RIGHT BEARING 100 00:06:50,416 --> 00:06:52,417 IN THE RIGHT CONROD. 101 00:06:54,246 --> 00:06:57,572 HE ASSEMBLES THE CONROD TO THE PISTONHEAD 102 00:06:57,574 --> 00:06:59,641 WITH A PURPOSE-BUILT MACHINE. 103 00:06:59,643 --> 00:07:01,969 THE MACHINE SCANS THE CONNECTING ROD 104 00:07:01,971 --> 00:07:05,932 FROM ABOVE TO VERIFY ONCE AGAIN THAT IT'S THE RIGHT PART. 105 00:07:09,195 --> 00:07:10,795 HE PLACES THE PISTONHEAD 106 00:07:10,797 --> 00:07:14,990 IN A VISE DESIGNED TO COMPRESS THE RINGS. 107 00:07:14,992 --> 00:07:16,992 A LIFT ASSIST HELPS THE TECHNICIAN 108 00:07:16,994 --> 00:07:18,986 BRING THE CRANKSHAFT TO THE ENGINE BLOCK 109 00:07:18,988 --> 00:07:21,156 AND LOWER IT IN PLACE. 110 00:07:24,253 --> 00:07:27,312 HE ROTATES THE BLOCK ON ITS ASSEMBLY FIXTURE 111 00:07:27,314 --> 00:07:30,441 TO GAIN ACCESS TO THE PISTON BORE HOLES. 112 00:07:33,345 --> 00:07:36,204 HE CAREFULLY INSTALLS SIX PISTONS IN THEIR BORES 113 00:07:36,206 --> 00:07:38,132 ONE BY ONE. 114 00:07:42,064 --> 00:07:43,329 ONCE THEY'RE IN PLACE, 115 00:07:43,331 --> 00:07:46,958 HE TURNS THE BLOCK AGAIN TO INSTALL THE CONROD CAPS 116 00:07:46,960 --> 00:07:49,987 USING A TORQUING DEVICE TO TIGHTEN THEM. 117 00:07:52,223 --> 00:07:54,749 HE MANUALLY ROTATES THE CRANKSHAFT TO MAKE SURE 118 00:07:54,751 --> 00:07:58,086 THE PISTONS MOVE SMOOTHLY. 119 00:07:58,088 --> 00:08:00,213 A FULLY AUTOMATED STATION BRINGS 120 00:08:00,215 --> 00:08:03,041 THE UPPER AND LOWER SECTIONS OF THE ENGINE BLOCK TOGETHER 121 00:08:03,043 --> 00:08:05,444 AND BOLTS THEM SECURELY. 122 00:08:05,446 --> 00:08:08,973 THE BOLTING PROCESS IS PERFECTLY SYNCHRONIZED 123 00:08:08,975 --> 00:08:11,967 TO MAKE THE BEST CONNECTION POSSIBLE. 124 00:08:11,969 --> 00:08:13,969 PORSCHE HAS DESIGNED FAIL-SAFE FEATURES 125 00:08:13,971 --> 00:08:19,392 INTO THE MANUFACTURING PROCESS TO PREVENT ASSEMBLY ERRORS. 126 00:08:19,394 --> 00:08:21,261 GUIDE PINS ON A LIFT ASSIST 127 00:08:21,263 --> 00:08:24,189 HELP THE OPERATOR POSITION THE CYLINDER HEAD. 128 00:08:26,060 --> 00:08:28,518 A TECHNICIAN DROPS THE CYLINDER HEAD BOLTS 129 00:08:28,520 --> 00:08:31,247 INTO THEIR POSITIONS BEFORE TORQUING THEM DOWN 130 00:08:31,249 --> 00:08:33,216 ONE BY ONE. 131 00:08:35,745 --> 00:08:38,545 HE GREASES THE CYLINDER HEADS TO PREPARE THEM 132 00:08:38,547 --> 00:08:41,941 FOR THE CAMSHAFT INSTALLATION. 133 00:08:41,943 --> 00:08:44,603 THE TECHNICIAN CAREFULLY PLACES THE CAMSHAFTS 134 00:08:44,605 --> 00:08:46,137 OVER THE CYLINDER HEADS. 135 00:08:46,139 --> 00:08:49,733 HE LOCKS IT IN PLACE WITH A JIG, THEN BOLTS IT DOWN. 136 00:08:53,497 --> 00:08:56,824 A WORKER POSITIONS THE PANAMERA'S TIMING CHAIN, 137 00:08:56,826 --> 00:09:01,754 CAREFULLY THREADING IT ONTO THE CAMSHAFT ADJUSTERS. 138 00:09:01,756 --> 00:09:05,616 THE CHAINS OPTIMIZE THE TIMING FOR DIFFERENT LOADS, 139 00:09:05,618 --> 00:09:07,844 ENSURING THE ROTATION OF THE CRANKSHAFT 140 00:09:07,846 --> 00:09:11,514 AND THE CAMSHAFT ARE PERFECTLY SYNCHRONIZED. 141 00:09:16,905 --> 00:09:19,506 THE TIMING CASE IS MADE OF MAGNESIUM, 142 00:09:19,508 --> 00:09:22,234 WHICH IS 33% LIGHTER THAN ALUMINUM 143 00:09:22,236 --> 00:09:26,063 AND 75% LIGHTER THAN STEEL. 144 00:09:26,065 --> 00:09:28,198 A TECHNICIAN FINISHES THE OPERATION 145 00:09:28,200 --> 00:09:32,387 BY INSTALLING THE CYLINDER HEAD COVER AND IGNITION COILS. 146 00:09:36,451 --> 00:09:39,318 THE V-6 ENGINE OF THE PORSCHE PANAMERA S 147 00:09:39,320 --> 00:09:42,380 IS NEARLY DONE. 148 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. 150 00:09:47,413 --> 00:09:50,139 HE USES A TORQUE-CONTROLLED BOLTING DEVICE 151 00:09:50,141 --> 00:09:54,201 TO RUN DOWN THE SCREWS AND BOLT IT SECURELY IN PLACE. 152 00:09:58,132 --> 00:10:01,558 THE COMPLETED V-6 CAN TAKE THE PANAMERA S 153 00:10:01,560 --> 00:10:04,829 FROM ZERO TO 60 IN JUST 5.1 SECONDS, 154 00:10:04,831 --> 00:10:09,092 WITH A TOP SPEED OF ALMOST 180 MILES PER HOUR. 155 00:10:14,283 --> 00:10:17,150 THE ENGINE JOINS THE REST OF THE POWER TRAIN 156 00:10:17,152 --> 00:10:20,179 ON A YELLOW SUBASSEMBLY WAGON. 157 00:10:20,181 --> 00:10:21,839 AS THE WAGON MOVES ON ITS TRACK, 158 00:10:21,841 --> 00:10:24,174 MEMBERS OF THE PORSCHE PRODUCTION TEAM 159 00:10:24,176 --> 00:10:26,002 COMPLETE THE ASSEMBLY. 160 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 162 00:10:31,967 --> 00:10:35,328 THAT ATTACH THE PROP SHAFT TO THE TRANSMISSION. 163 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, 165 00:10:41,661 --> 00:10:43,920 THE EXHAUST IS A LIGHTWEIGHT SYSTEM, 166 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, 170 00:10:56,010 --> 00:10:58,736 TURBO CHARGING, RECUPERATION, 171 00:10:58,738 --> 00:11:00,271 AUTO START-STOP, 172 00:11:00,273 --> 00:11:02,206 AND A COASTING FUNCTION 173 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 176 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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