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Narrator:
When it comes to construction,
Renovation, or simply repairs,
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Whether you're a seasoned pro
Or a do-it-yourselfer,
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Having the right tools
Makes the job easier.
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Sawhorses support the piece
Of wood you're cutting,
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And a toolbox keeps
Your implements
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Organized and portable.
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Sawhorses are always sold
In pairs
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Because you need two
Under a piece of wood
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To stabilize it for cutting.
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By pulling
The hinged tray upward,
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The sawhorse collapses flat
For transport and storage.
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This model is made from pellets
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Of an exceptionally strong
Type of polypropylene plastic.
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A vacuum system
Draws the pellets into
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An injection-molding machine.
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The machine melts them
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Then shoots the liquid
Into a mold.
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It takes about a minute
For the liquid to solidify,
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At which point
The mold automatically opens,
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And an articulated robotic arm
Removes the parts --
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For each sawhorse, two halves,
The legs, and two panels
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Which form
The collapsible hinged tray
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That holds those legs open.
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The robot drops those parts
At the first assembly station,
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00:02:09,000 --> 00:02:12,827
Where a worker joins each panel
To a sawhorse half
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00:02:12,827 --> 00:02:15,413
And applies non-slip footpads.
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These pads help
Keep the sawhorse stable
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00:02:18,931 --> 00:02:21,344
And protect the floor
From scratches.
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00:02:21,344 --> 00:02:25,241
The worker lays out the parts
For both sides of the sawhorse
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In a positioning fixture
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Then activates the press
A couple of times
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To snap the parts together.
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At the next station, a worker
Inserts ribbed rubber pads
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Into molded holes
On top of each sawhorse half.
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These anti-slip pads help hold
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Large pieces of wood steady
On the sawhorse.
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Next, he lays both sawhorse
Halves on the work table
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And with a tool
Called a stamping arm,
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Snaps the two panels together.
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This forms a strong hinge,
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Which opens and collapses
The tray.
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The sawhorse is now finished
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And heads
To the packaging station.
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There, a worker stacks
Two sawhorses,
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Then, with a foot pedal,
Activates a machine
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Which binds them
With a plastic strap.
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Then she tapes on
A wrap-around label.
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Have tools, will travel.
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This two-piece toolbox
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Consists of a large storage tub
On the bottom
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And a spacious toolbox on top.
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Like a rolling suitcase,
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It has two large
Polypropylene wheels
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With molded-on rubber treads
And a collapsible pull handle.
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A toolbox doesn't
Have to withstand pressure
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Bearing down on it,
So it's made of standard,
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00:04:03,275 --> 00:04:06,034
Rather than high-strength,
Polypropylene.
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The injection-molding process
Is the same.
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The storage tub,
The toolbox bottom,
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And the toolbox lid
Are each molded separately.
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In the assembly area,
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Workers apply an adhesive label
On the front of the toolbox
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Then install the latches
For locking the lid.
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The latches
Slide into molded slots.
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After inserting
A removable tray,
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Workers install the lid
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With a few strikes of
A non-marring urethane hammer.
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Both lid and latches
Snap in easily
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Because the polypropylene
Is still hot and flexible.
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Once it cools and becomes rigid,
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The lid and latches
Can't dislodge.
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To assemble each wheel,
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Workers position a star nut
And steel axle into the wheel,
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Then, with an assembly ram,
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Press the axle into the star nut
To lock the parts together.
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They snap a wheel onto each side
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Of the tub portion
Of the toolbox,
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Then, with a press,
Force the wheels
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Into their final
Locked position.
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Once the toolbox
And tub portions
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Are each separately assembled,
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Workers hang a parts tray
On the rim of the tub
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Then sit the toolbox on the tray
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And lock it in place
With two large side hinges.
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And that completes construction
Of this workshop on wheels.
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Narrator: traditionally,
Sorbets have been dished up
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Between courses
To refresh the palate,
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But served in a squeezed-up pop,
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A sorbet becomes a snack
You can grab anytime --
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No need for scoops, spoons,
Or dishes.
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Just squeeze the sorbet
Out of the paper sleeve.
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Now that's refreshing.
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A long favorite of foodies,
Fruit sorbet has gone mainstream
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With these squeeze-up pops.
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More fun
Than a few scoops in a dish,
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Sorbet pops are also
Lower in calories
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Than a lot of other snacks.
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They start
With freeze-dried rice syrup.
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They pour it into a mixing vat
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That's a mega version
Of a home blender.
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They add strawberry puree.
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This is the main ingredient
Of the sorbet pops.
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The berries were pulped
Within 12 hours of harvest.
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The next ingredient
Is cane sugar.
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It's followed
By strawberry essence --
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Compounds extracted
From the berries
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For more intense flavor.
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They turn on the tap
For the final ingredient --
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Water.
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It's time to close the lid
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And power up
This industrial blender.
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The mixer has four blades
That turn at a high velocity.
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They whip up
The sorbet ingredients
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To the consistency
Of a fruit smoothie.
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The sorbet mixture then flows
Into refrigerated pipes
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That chill the mixture
To 40 degrees fahrenheit.
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The pipes
Wind around the factory
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And finally deliver it
To holding tanks.
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Inside, an agitator
Swirls the chilled mixture
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To maintain
The smoothie-like consistency.
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Once a tank is full,
A technician tests the acidity
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And the level of suspended
Sugars in the mixture.
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If the levels are right,
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They transfer the mixture
Into a continuous freezer.
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It pumps air
Into the sorbet mix,
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And it churns and scraps it
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Against the freezing-cold walls
Of the machine.
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Cool water
Runs through the motor
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00:08:16,965 --> 00:08:20,000
To keep it from overheating
As it freezes the sorbet.
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This is only a partial freezing
To keep the sorbet
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Soft enough to be pumped
Into the paper squeeze tubes.
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A device
With little robotic fingers
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Pries the papers tubes
From a stack
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00:08:33,896 --> 00:08:37,379
And deposits them
In slots in a moving tray.
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The tubes
Are in position to receive
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The partially frozen sorbet,
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And because the sorbet
Is only partially frozen,
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It is able to now flow
Through conduits.
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Frozen solid,
It couldn't make the journey
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To the squeeze tubes.
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As the sorbet is pumped
Into the paper sleeves,
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Its temperature is critical.
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It is precisely
37.8 degrees fahrenheit.
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One degree cooler
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And it would be too thick
To pump.
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A degree warmer,
And ice crystals would form
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During the final freezing.
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The next machine
Collects foil lids from a pack,
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Using rubber heads
With tiny magnets in the center.
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It deposits the lids
Onto the sorbet-filled tubes.
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The foil lids stick
To the glue-coated rims.
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This line fills
280 paper sleeves
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With fruit sorbet per minute.
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That's just under
17,000 per hour.
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An iron applies heat to the lids
To further melt the glue
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And provide a water-tight seal.
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It happens fast
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So the sorbet doesn't have time
To start melting.
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Sealed and partially frozen,
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The sorbet pops
Cascade into crates.
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Each one holds about 100 pops,
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So they don't need
To keep count.
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And then it's into
The blast freezer,
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Also know as the shock freezer.
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Fans circulate the cold air
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To rapidly lower the temperature
Of the sorbet pops,
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Bringing it down
To -24 degrees fahrenheit.
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This fast freezing prevents
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The formation
Of large ice crystals
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That would damage
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The consistency and flavor
Of the sorbet pops.
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Out of the freezer,
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A mechanized arm grabs and opens
Cardboard boxes.
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A pusher shoves the sorbet pops
Into the boxes.
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And they're ready
To grab and squeeze.
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Narrator:
The big yellow school bus
Puts millions of children
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On the road to an education.
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It all started
In the 19th century
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With horse-drawn trucks
Known as kid hacks.
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00:11:18,827 --> 00:11:21,724
The word "Hack" was short
For hackney carriage.
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00:11:21,724 --> 00:11:24,275
In the 20th century,
They were motorized
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And became known
As school buses.
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Every school day,
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Children across north america
Wait for the school bus.
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Appearance-wise,
It's hard to miss.
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Big and yellow,
It is deliberately conspicuous,
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Designed to stand out in traffic
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So other drivers
Slow down and take notice.
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Manufacturing starts
With a support structure --
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The steel underframe.
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00:11:55,172 --> 00:11:57,724
They arrange several short rails
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00:11:57,724 --> 00:12:00,862
Down the top
Of two long frame rails.
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00:12:00,862 --> 00:12:04,413
These cross rails
Will link the long rails
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00:12:04,413 --> 00:12:06,827
And provide strategic support.
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00:12:06,827 --> 00:12:09,655
Using the lift,
They raise the long rails,
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00:12:09,655 --> 00:12:12,310
And the cross rails
Slide into position
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00:12:12,310 --> 00:12:14,862
Just under the rims
Of the long ones.
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00:12:14,862 --> 00:12:18,620
Now, in a fixture
That pins the rails together,
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00:12:18,620 --> 00:12:20,758
Workers bolt them together.
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00:12:20,758 --> 00:12:25,896
With the school-bus underframe
Assembled, they roll in
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00:12:25,896 --> 00:12:30,379
Two enormous wheel axles
Complete with brakes.
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00:12:30,379 --> 00:12:33,241
Overhead cables
Lift the bus frame
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00:12:33,241 --> 00:12:36,827
And workers guide it into place
On the axles.
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00:12:43,931 --> 00:12:46,413
They attach the axles
To the frame
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00:12:46,413 --> 00:12:51,586
With metal brackets, shackles,
And spacers where needed.
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00:12:51,586 --> 00:12:54,896
The chassis is ready
For the engine.
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00:12:54,896 --> 00:12:58,551
They lower it
Onto the front of the frame
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00:12:58,551 --> 00:13:00,724
And secure it with bolts.
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00:13:00,724 --> 00:13:04,551
The school-bus engine
Packs a lot of power.
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00:13:04,551 --> 00:13:07,965
It's diesel-fueled
With six cylinders.
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00:13:07,965 --> 00:13:10,000
Next up
Is the front cal assembly,
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00:13:10,000 --> 00:13:12,137
Which includes
The instrument panel
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00:13:12,137 --> 00:13:14,172
And steering column.
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00:13:14,172 --> 00:13:16,620
A workers
Wires the steering wheel
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00:13:16,620 --> 00:13:21,586
To the controls in the column
And slides it into place.
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00:13:21,586 --> 00:13:24,068
They mount the tires and rims --
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00:13:24,068 --> 00:13:28,517
Four on the back axle to handle
The heavier passenger load
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00:13:28,517 --> 00:13:30,206
And two on the front.
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00:13:32,310 --> 00:13:33,965
Using a multi-pronged tool,
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00:13:33,965 --> 00:13:36,137
The worker
Tightens numerous nuts
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00:13:36,137 --> 00:13:38,344
To fasten the wheels
To the axles.
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00:13:42,689 --> 00:13:46,379
They now encase the engine
With a fiberglass hood.
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00:13:46,379 --> 00:13:48,517
The hood has been pre-painted
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00:13:48,517 --> 00:13:51,068
And equipped with cross-view
Mirrors and headlights.
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00:13:51,068 --> 00:13:54,482
They bolt it
To the vehicle frame,
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00:13:54,482 --> 00:13:58,344
And after adding antifreeze
And coolant,
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00:13:58,344 --> 00:14:01,310
The bus is technically drivable.
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00:14:01,310 --> 00:14:03,758
They roll it over
To a test station
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00:14:03,758 --> 00:14:05,413
To check the brakes.
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00:14:09,896 --> 00:14:14,137
The wheels turn on rollers
So the bus runs in one spot.
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00:14:14,137 --> 00:14:16,517
A computer monitors
The performance
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00:14:16,517 --> 00:14:18,758
Of both the front
And back brakes
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00:14:18,758 --> 00:14:20,344
As a driver applies them.
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00:14:23,137 --> 00:14:27,310
They now move on
To build the school-bus body.
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00:14:27,310 --> 00:14:30,103
The body starts with the floor.
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00:14:30,103 --> 00:14:33,931
They unwind
Double-sided galvanized steel
237
00:14:33,931 --> 00:14:37,827
Into a machine
That slices it into panels.
238
00:14:37,827 --> 00:14:41,068
It also cuts holes
To be used for assembly.
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00:14:41,068 --> 00:14:43,689
A forming machine
Folds the sides
240
00:14:43,689 --> 00:14:45,517
To create support beams.
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00:14:45,517 --> 00:14:51,275
Two more steel beams will really
Stiffen the floor panel.
242
00:14:51,275 --> 00:14:55,931
A worker positions those beams
On the panel,
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00:14:55,931 --> 00:14:59,482
And an automated machine
Welds them to it.
244
00:14:59,482 --> 00:15:03,862
It feeds the floor panel
To the welder incrementally
245
00:15:03,862 --> 00:15:07,896
So it can spot weld
Down the length of the beams.
246
00:15:13,482 --> 00:15:16,413
It takes dozens of welds
To solidly secure
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00:15:16,413 --> 00:15:18,310
The steel supports.
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00:15:20,413 --> 00:15:26,344
And with those reinforcements,
The floor panel is complete.
249
00:15:26,344 --> 00:15:29,344
It's ready for assembly.
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00:15:29,344 --> 00:15:33,206
Workers arrange several panels
Upside down
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In a precise configuration.
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Then it's into
A second automated welder
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00:15:39,379 --> 00:15:42,896
That joins them
To make one school-bus floor.
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00:15:42,896 --> 00:15:46,206
After manually welding pockets
For wheels,
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00:15:46,206 --> 00:15:50,275
A machine called the floor flip
Picks up the bus floor
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00:15:50,275 --> 00:15:52,241
And turns it rightside up.
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They're now ready to build
The passenger compartment,
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So stay tuned.
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00:16:17,620 --> 00:16:19,482
Narrator: a school bus
Transports precious cargo --
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00:16:19,482 --> 00:16:20,517
Children.
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00:16:20,517 --> 00:16:23,482
To hold the average bus
Together,
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00:16:23,482 --> 00:16:27,896
They use an incredible
6,100 rivets, bolts, and screws
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00:16:27,896 --> 00:16:30,068
And make a total of 840 welds.
264
00:16:30,068 --> 00:16:32,275
For the maker of school buses,
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00:16:32,275 --> 00:16:34,931
There's strength
In those numbers.
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00:16:38,827 --> 00:16:39,965
To build the frame
267
00:16:39,965 --> 00:16:42,206
For the school-bus walls
And ceiling,
268
00:16:42,206 --> 00:16:44,586
They bend steel beams
Into bow shapes.
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00:16:44,586 --> 00:16:49,931
A hydraulic machine with pushers
Does the job in seconds,
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00:16:49,931 --> 00:16:52,448
Achieving an exact radius.
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00:16:56,896 --> 00:17:01,827
The bows will serve as ribs
For the school-bus body.
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00:17:03,931 --> 00:17:07,103
They make several bows
For each bus.
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00:17:07,103 --> 00:17:11,655
The precise number depends on
The bus size and capacity.
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00:17:11,655 --> 00:17:14,586
Workers plug
The ends of the bows
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00:17:14,586 --> 00:17:18,965
Into holes in steel rails
And secure them with bolts.
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00:17:18,965 --> 00:17:22,206
They weld lateral supports
Higher up,
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00:17:22,206 --> 00:17:26,103
And the cage-like skeleton
Of the school bus takes shape.
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00:17:28,241 --> 00:17:32,103
They're now ready
To build on this framework.
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00:17:32,103 --> 00:17:35,689
They attach
The metal windshield surround.
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00:17:35,689 --> 00:17:37,827
The team then moves
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00:17:37,827 --> 00:17:42,655
The steel side sheets
And skirting into place.
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00:17:42,655 --> 00:17:47,172
They secure these panels
With super-strong adhesive
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00:17:47,172 --> 00:17:49,793
And numerous rivets.
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00:17:53,793 --> 00:17:55,758
Using cables and nylon straps,
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00:17:55,758 --> 00:17:58,724
They pull steel sheets
To the roof structure
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00:17:58,724 --> 00:18:01,310
To make them conform
To the contours.
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00:18:03,413 --> 00:18:05,931
The steel is 20-gage --
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00:18:05,931 --> 00:18:11,068
A grade that's flexible enough
To be easily bent.
289
00:18:11,068 --> 00:18:14,413
The cables hold the steel panels
Tightly to the roof structure
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00:18:14,413 --> 00:18:16,482
While the workers
Rivet them to it.
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00:18:16,482 --> 00:18:20,034
The number of rivets
And the strength of the joints
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00:18:20,034 --> 00:18:23,103
Are among many
Government safety standards
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00:18:23,103 --> 00:18:24,896
The school bus must meet.
294
00:18:24,896 --> 00:18:27,034
Working from the inside,
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00:18:27,034 --> 00:18:30,931
They glue fiberglass insulation
Into the pockets of the cage
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00:18:30,931 --> 00:18:34,206
To keep the bus warm in winter
And cool in summer.
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00:18:34,206 --> 00:18:37,103
The insulation
Will also muffle road noise
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00:18:37,103 --> 00:18:39,724
And absorb
Some of the student chatter
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00:18:39,724 --> 00:18:42,586
For a quieter ride.
300
00:18:42,586 --> 00:18:45,931
The team installs steel panels
On the ceiling.
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00:18:45,931 --> 00:18:48,620
These panels
Have tiny perforations
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00:18:48,620 --> 00:18:51,862
To allow sound to escape
Into the insulation.
303
00:18:53,965 --> 00:18:56,655
They tape up
The windows and doors
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00:18:56,655 --> 00:18:58,241
And sand some areas
305
00:18:58,241 --> 00:19:02,965
As they now prepare to paint
The exterior of the bus.
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00:19:02,965 --> 00:19:05,689
The paint, national bus yellow,
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00:19:05,689 --> 00:19:08,965
Takes the metal
From dull to bold.
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00:19:08,965 --> 00:19:12,896
This shade was developed
Specifically for school buses
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00:19:12,896 --> 00:19:16,344
And can be noticed
Even with peripheral vision.
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00:19:19,586 --> 00:19:24,000
With the paint now dry,
They open the doors
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00:19:24,000 --> 00:19:26,517
And lay
A plywood subfloor inside.
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00:19:26,517 --> 00:19:28,241
It too will absorb noise.
313
00:19:28,241 --> 00:19:30,724
An employee drives the chassis
314
00:19:30,724 --> 00:19:34,482
Over to the school-bus-body
Production line,
315
00:19:34,482 --> 00:19:35,724
And parks it.
316
00:19:37,827 --> 00:19:41,517
Using cables,
They lift the bus body
317
00:19:41,517 --> 00:19:43,551
Over to the chassis.
318
00:19:43,551 --> 00:19:47,137
At over three and a half tons,
It's hefty.
319
00:19:50,586 --> 00:19:53,827
They gently lower it
Onto the frame rails
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00:19:53,827 --> 00:19:56,137
And mate the front to the hood.
321
00:19:58,275 --> 00:20:02,517
They tie the body to the frame
With heavy-duty clips.
322
00:20:02,517 --> 00:20:04,517
They arrange the seating
323
00:20:04,517 --> 00:20:08,103
To surround the passengers
With cushioning.
324
00:20:08,103 --> 00:20:11,827
This creates compartments
Around the occupants
325
00:20:11,827 --> 00:20:15,137
To protect them in a collision.
326
00:20:15,137 --> 00:20:19,310
Outside, a worker applies
School-bus lettering.
327
00:20:23,965 --> 00:20:25,310
Another worker presses
328
00:20:25,310 --> 00:20:27,931
An adhesive-backed
Manufacturer's emblem
329
00:20:27,931 --> 00:20:28,931
To the hood.
330
00:20:28,931 --> 00:20:30,275
They equip the bus
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00:20:30,275 --> 00:20:33,000
With the flashing lights
And stop signs
332
00:20:33,000 --> 00:20:35,655
To get the attention
Of other drivers
333
00:20:35,655 --> 00:20:38,448
When children
Are loading and unloading.
334
00:20:38,448 --> 00:20:41,413
They also install
A crossing gate to keep children
335
00:20:41,413 --> 00:20:43,620
Within the bus driver's
Sight line.
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00:20:45,724 --> 00:20:48,827
They test
All of the warning lights
337
00:20:48,827 --> 00:20:50,551
And safety devices.
338
00:20:54,655 --> 00:20:57,275
And satisfied
That everything is operational,
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00:20:57,275 --> 00:21:00,758
The bus rolls
Off the production line.
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00:21:00,758 --> 00:21:04,448
It's taken a day and a half
To build it,
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00:21:04,448 --> 00:21:07,655
And when it comes to
An education,
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00:21:07,655 --> 00:21:10,103
It's ready to deliver.
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00:21:21,551 --> 00:21:23,689
If you have any comments
About the show,
344
00:21:23,689 --> 00:21:26,344
Or if you'd like to suggest
Topics for future shows,
345
00:21:26,344 --> 00:21:28,724
Drop us a line at...
346
00:21:31,931 --> 00:21:34,931
--captions by vitac--
Www.Vitac.Com
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00:21:34,931 --> 00:21:37,896
Captions paid for by
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