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Narrator: A hot sauce
making super scale history
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On a salt dome in louisiana.
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♪♪
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Inside this online giant,
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How amazon processes millions
of orders at lightning speed.
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♪♪
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Kia, a south korean
car manufacturer
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Are breaking records
in slovakia.
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And in south korea,
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The world's largest steel plant
is melting iron ore
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To keep the world supplied
with this versatile alloy.
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These groundbreaking innovations
are all taking place
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Inside some of the most
incredible factories
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On the planet.
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-- Captions by vitac --
www.Vitac.Com
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Captions paid for by
discovery communications
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[ beeping ]
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This is avery island,
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137 miles west
of new orleans,
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The heart of bayou country.
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This is the home
of an iconic sauce brand
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That's been heating
up the world for 150 years --
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Tabasco.
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Today, the spicy red hot
liquid is grown,
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Processed, and sold
on a super scale
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From a self-sufficient farm
on the island.
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700,000 bottles a day
are produced
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By using a centuries
old family recipe.
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♪♪
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Sixth generation family member
john simmons manages the crops.
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So we're here on avery island,
on our farm,
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Our process from seed to bottle
takes about five years
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And this is the beginning
of it right here.
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Every pepper that goes into
the making of tabasco sauce
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Comes from seed that are grown
right here on avery island.
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Narrator:
The chilies grown here
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Are specifically
tabasco chilies,
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A variety that originated
far away from u.S. Soil.
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The founder, edmund mcilhenny,
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Got hold of pepper seeds
from central america.
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He sold them on avery island.
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And as it turns out, the taste
is just what he was looking for.
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Narrator: Mcilhenny grew his
first commercial pepper crop
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In 1868.
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The next year,
he sent out 658 bottles
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Of sauce at a dollar apiece.
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Today, the seeds are chosen
from a cultivated crop.
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As near as we know,
those seeds are identical
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To the seeds
that edmund mcilhenny,
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My great-great-great
grandfather with,
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Started 150 years ago.
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We do our seed here
because we can make sure
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That that seed is perfect,
that it's exactly what we want.
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We'll come out here
and look at those plants
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And we'll pick the best ones,
the strongest ones.
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And we'll say these plants here
are the ones
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That we want to make
our seed crop with.
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Narrator: Avery island doesn't
have the space or staff to grow
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And pick all the chilies
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Needed to supply
the global tabasco industry.
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So the seeds are sent
all around the world to grow.
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But central america is where
most of the chilies used today
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Are cultivated.
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Pickers ensure ripeness
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By comparing
the color of the peppers
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To a small wooden dowel
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Which is painted the preferred
hue of tabasco red.
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The color indicates whether
or not it's the optimum time
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To pick in order to ensure
maximum heat.
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Once picked,
they're mashed up with salt.
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After a month of fermenting,
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The mash is then shipped back
to avery island,
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Where it's poured into these
80-year-old wooden barrels.
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So we're in the mash warehouse
sometimes we call it
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The barrel warehouse,
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And this is the building that
really sets tabasco sauce apart
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Because we take two of our
three raw ingredients
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And we age them in oak barrels
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For up to three years
to give tabasco sauce
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That unique flavor
and unique smell
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That people all around
the world know.
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We have between 65,000
and 70,000 barrels.
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In this building
and here we have about 15
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Or 20,000 barrels
at any given time.
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And then we have a building
next door with all the rest.
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That's a three-year supply
of tabasco sauce
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Right here on avery island.
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Narrator: Over the years,
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The mash and salt
will break down.
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Fermentation is an ancient
method of food preservation,
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And it's an amazing process.
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It kills off bacteria,
which is harmful to food,
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Which would make food decay.
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But the great news is
it encourages bacteria,
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Which makes food
tastes delicious.
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Edmund mcilhenny started
with clay jars
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00:05:03,304 --> 00:05:04,870
And then he moved
to using oak barrels
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00:05:04,872 --> 00:05:07,873
And he found that oak barrels
imparted a flavor
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And a color and a smell
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That was really powerful
and interesting.
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Narrator: Before the mix
can be left to ferment,
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They have to complete
a crucial part of the process,
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Covering each barrel
with a thick layer of salt,
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Which is extracted from mines
located beneath avery island.
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The enemy of pepper mash
is oxygen, oxygen and sunlight,
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Those are the things
we want to keep out.
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So the best way
we can keep oxygen out
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Is to close up that container
seal it as tight as possible
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And put this block on top.
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But we need a permeable thing
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Because there's carbon dioxide
being created inside that barrel
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And we need a place
for it to go.
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So there's a one way valve
that you can't see
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Covered by this block of salt,
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But that salt
is permeable enough
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To allow that carbon dioxide
through it.
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If we didn't have that,
the pressure would build up
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Inside that barrel
and it would explode.
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Salt has been used
as a preservative
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For thousands of years.
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Now salt dries out food
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00:06:06,166 --> 00:06:10,035
And all living things
require water to grow,
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Including bacteria,
harmful bacteria,
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Which can create
food poisoning.
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So salting food not only
makes it last a long time,
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It makes it safe.
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Narrator: The three-year
fermentation process
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Is the only change
to the original recipe,
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Which mandated fermenting
for just 30 days.
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Every morning,
a team member checks the batch
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That will become
today's sauce.
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Simmons: Here we have a barrel,
three years old.
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This is ready to be turned
into tabasco sauce.
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00:06:43,570 --> 00:06:45,137
So you can see a few things.
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We've got this really,
really deep red color.
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And the other thing you can see
is how much evaporation
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We've had inside the barrel.
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The whiskey companies call
that the angel share,
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The evaporation of whiskey
inside the barrel.
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We call it the same thing,
essentially.
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It's the evaporation
of tabasco pepper mash,
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The moisture inside tabasco
pepper mash inside that barrel.
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♪♪
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Narrator: The fermented mash
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That is ready
to be turned into sauce
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Is pumped into big steel vats
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00:07:11,932 --> 00:07:15,167
Where it's drained of remaining
moisture for eight hours,
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Losing 25% of its weight.
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Then it's pumped
into 2,600 gallon wooden barrels
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And churned with vinegar.
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The acidity of the vinegar
breaks down most of the pulp,
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And the liquid is strained
to remove skins and seeds.
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♪♪
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Tabasco sauce is graded
for hotness.
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Here they use
the scoville scale.
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It was invented by pharmacist
wilbur scoville in 1912
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And measures the level
of capsaicinoids.
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This is the component
of chili peppers responsible
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For most of the burn.
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In our mouth, our receptors,
which can detect heat,
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Now, they can detect
actual heat,
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00:08:01,515 --> 00:08:05,617
But they can also detect heat
from food like chilies.
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Capsaicin, which is the chemical
compound found in foods
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Like chilies and peppers,
actually fools our bodies
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Into thinking that
we've eaten something hot,
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Hot to touch that burns,
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Even though
is actually a food.
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♪♪
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Narrator: The flagship red
variety of tabasco pepper sauce
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Measures 2,500 to 5,000
scoville heat units.
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Our hottest sauce right now
is our scorpion sauce
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That comes in and around
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33 to 35,000
scoville heat units.
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Just under that
is our habanero sauce,
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Which is about 9,000.
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Narrator: Each sauce is tested
by a panel of 20 employees.
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We do some pretty rigorous
sensory testing that way
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And it has to get the thumbs up
from everyone
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Before we go ahead
with it to market.
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Narrator:
Once it passes the test,
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It's sent to be bottled.
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And this is where modern
production methods kick in.
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♪♪
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There are 720 drops in a single
bottle of tabasco sauce
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And 700,000 bottles of sauce
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Are produced here
in a single day.
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The signature bottle derives
from the original ones
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Used in 1858,
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Which were based on a perfume
bottle produced in new orleans.
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It takes five years
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To produce a bottle
of finished sauce.
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It's a highly complex process
with global ends,
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Labels are printed
in 22 different languages,
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And exported to over
180 different countries.
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As long as this super factory
holds the secret to tabasco,
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They'll be producing it
for centuries to come.
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♪♪
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But while tabasco
has spent 150 years
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00:10:02,235 --> 00:10:04,169
Perfecting one product,
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00:10:04,171 --> 00:10:07,172
This next company has spent
the last two decades
201
00:10:07,174 --> 00:10:12,611
Attempting to corner the market
on every product imaginable.
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00:10:12,613 --> 00:10:16,848
By using the latest and greatest
industrial technology available
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00:10:16,850 --> 00:10:19,851
And relying on a steadily
growing workforce,
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00:10:19,853 --> 00:10:24,422
Amazon has revolutionized
the online shopping industry.
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00:10:24,424 --> 00:10:30,762
♪♪
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00:10:30,764 --> 00:10:33,331
In northern England
lies a facility
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00:10:33,333 --> 00:10:36,935
Whose interior doesn't look like
a traditional factory,
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00:10:36,937 --> 00:10:39,938
But that's because the people
and machinery here
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00:10:39,940 --> 00:10:44,476
Are working to transform
modern production methods.
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00:10:44,478 --> 00:10:49,514
This is amazon, a company
that's part of what experts call
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00:10:49,516 --> 00:10:52,584
The fourth
industrial revolution.
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00:10:52,586 --> 00:10:56,254
Here, they use high levels
of automation,
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00:10:56,256 --> 00:10:59,724
But that doesn't
mean fewer people.
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00:11:01,762 --> 00:11:06,064
♪♪
215
00:11:06,066 --> 00:11:08,700
Narrator: The amazon factory
in northern England
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00:11:08,702 --> 00:11:12,570
Is a pioneer in the fourth
industrial revolution,
217
00:11:12,572 --> 00:11:15,674
Using technology
to maximize productivity
218
00:11:15,676 --> 00:11:18,076
And minimize mistakes.
219
00:11:18,078 --> 00:11:21,312
But they haven't abandoned
their human workforce.
220
00:11:21,314 --> 00:11:25,717
In fact, they're relying
on their workers more than ever.
221
00:11:25,719 --> 00:11:27,252
They've invested heavily
in robots
222
00:11:27,254 --> 00:11:29,821
To improve the efficiency
of their operation,
223
00:11:29,823 --> 00:11:31,523
But their staffing has gone up.
224
00:11:31,525 --> 00:11:35,560
The global workforce more than
doubled between 2016 and 2019
225
00:11:35,562 --> 00:11:38,229
To more than 650,000 people.
226
00:11:38,231 --> 00:11:39,998
They're now the second
biggest employer
227
00:11:40,000 --> 00:11:42,600
In the whole of the usa.
228
00:11:42,602 --> 00:11:45,603
Narrator: It all began when
ceo jeff bezos
229
00:11:45,605 --> 00:11:50,308
Started selling books
in his garage in 1994.
230
00:11:50,310 --> 00:11:53,812
With a net worth of
$113 billion,
231
00:11:53,814 --> 00:11:57,082
He has become
the world's wealthiest man,
232
00:11:57,084 --> 00:12:01,219
And amazon now controls
50% of online commerce
233
00:12:01,221 --> 00:12:05,423
In the united states.
234
00:12:05,425 --> 00:12:07,492
All over the world,
235
00:12:07,494 --> 00:12:11,229
Amazon is building giant
delivery facilities called
236
00:12:11,231 --> 00:12:14,833
Fulfillment centers or fcs.
237
00:12:14,835 --> 00:12:19,804
By 2019, 175 of amazon's fcs
238
00:12:19,806 --> 00:12:22,440
Were in operation.
239
00:12:22,442 --> 00:12:27,011
On the inside, it's a giant
machine with one task --
240
00:12:27,013 --> 00:12:30,081
To package parcels
in record time.
241
00:12:30,083 --> 00:12:31,549
When those robots are moving,
242
00:12:31,551 --> 00:12:34,819
It's like a ballet or a waltz,
they're definitely dancing.
243
00:12:34,821 --> 00:12:39,491
♪♪
244
00:12:39,493 --> 00:12:42,127
Narrator: One of amazon's
most modern fcs
245
00:12:42,129 --> 00:12:45,296
Is located in bolton, England,
246
00:12:45,298 --> 00:12:49,634
Covering almost 366,000
square feet,
247
00:12:49,636 --> 00:12:52,871
It's a state of the art facility
designed to ship
248
00:12:52,873 --> 00:12:57,742
Millions of packages
every year.
249
00:12:57,744 --> 00:13:01,146
Products arrive on
a constant stream of trucks
250
00:13:01,148 --> 00:13:04,883
Carrying any of
the 370 million products
251
00:13:04,885 --> 00:13:09,220
Currently listed on amazon
in the u.K.
252
00:13:09,222 --> 00:13:13,758
We have product coming over on
truckload coming from sellers,
253
00:13:13,760 --> 00:13:16,394
Vendors,
and from our own warehouses.
254
00:13:16,396 --> 00:13:20,665
It comes in where we upload this
and stage it on our yard,
255
00:13:20,667 --> 00:13:24,169
Ready to go into our warehouse
for storage
256
00:13:24,171 --> 00:13:26,871
Where it's gonna be ready
to ship for our customers.
257
00:13:26,873 --> 00:13:29,874
♪♪
258
00:13:29,876 --> 00:13:33,545
Narrator: Inside black plastic
tubs called totes,
259
00:13:33,547 --> 00:13:36,314
Products begin their journey
along a network
260
00:13:36,316 --> 00:13:38,650
Of five miles
of conveyor belts.
261
00:13:38,652 --> 00:13:41,419
♪♪
262
00:13:41,421 --> 00:13:44,656
The first destination
is the storage area.
263
00:13:44,658 --> 00:13:46,891
♪♪
264
00:13:46,893 --> 00:13:49,694
Where traditional warehouses
have static rows
265
00:13:49,696 --> 00:13:53,464
Of shelving with staff
walking back and forth,
266
00:13:53,466 --> 00:13:56,801
Here, it's the shelves
that do the walking.
267
00:13:56,803 --> 00:14:02,607
The key to this entire operation
is remote controlled robots.
268
00:14:02,609 --> 00:14:06,044
The orange devices pick up
the yellow shelf units
269
00:14:06,046 --> 00:14:08,780
And drop them off
at their next destination
270
00:14:08,782 --> 00:14:10,114
Within the warehouse.
271
00:14:51,124 --> 00:14:52,991
Narrator: There are thousands
of shelf units
272
00:14:52,993 --> 00:14:57,896
Supported by these robots.
273
00:14:57,898 --> 00:15:01,833
Every item is placed
by a picker on the shelves.
274
00:15:01,835 --> 00:15:06,704
It's given a barcode
so a robot can find it later.
275
00:15:06,706 --> 00:15:09,707
But crucially, the shelves
are deliberately stacked
276
00:15:09,709 --> 00:15:12,410
In a completely random way.
277
00:15:12,412 --> 00:15:15,446
This places items
all around the factory.
278
00:15:15,448 --> 00:15:18,049
So when robots or pickers
need something,
279
00:15:18,051 --> 00:15:21,352
They can get to a quicker.
280
00:15:21,354 --> 00:15:24,422
But that's not all they do,
281
00:15:24,424 --> 00:15:27,392
These robots do a neat little
bit of machine learning,
282
00:15:27,394 --> 00:15:30,929
Which is to realize if they
happen to have on board an item
283
00:15:30,931 --> 00:15:34,933
Which is currently trending
and is somehow proving popular
284
00:15:34,935 --> 00:15:36,267
Instead of returning back
to the middle,
285
00:15:36,269 --> 00:15:38,269
They actually hang around
the outside
286
00:15:38,271 --> 00:15:41,439
Expecting to be called
upon again.
287
00:15:41,441 --> 00:15:43,975
There's a direct link
between the customer
288
00:15:43,977 --> 00:15:45,610
As they shop online
289
00:15:45,612 --> 00:15:49,213
And what's happening here
on the floor.
290
00:15:58,291 --> 00:15:59,624
Once they're full,
291
00:15:59,626 --> 00:16:03,061
The shelf units disappear
back into the storage area
292
00:16:03,063 --> 00:16:07,432
Until someone maybe hundreds
or even thousands of miles away,
293
00:16:07,434 --> 00:16:11,436
Decides to purchase an item
stored on that particular shelf.
294
00:16:11,438 --> 00:16:14,706
♪♪
295
00:16:14,708 --> 00:16:16,441
As soon as that happens,
296
00:16:16,443 --> 00:16:20,144
A robot is directed to grab
that individual shelf unit
297
00:16:20,146 --> 00:16:24,582
Among thousands that contains
the specific item.
298
00:16:24,584 --> 00:16:28,920
♪♪
299
00:16:28,922 --> 00:16:31,489
It's then hurried over
to the picking area
300
00:16:31,491 --> 00:16:34,258
Where the journey to
the customer is about to begin.
301
00:16:34,260 --> 00:16:38,329
♪♪
302
00:16:38,331 --> 00:16:41,199
Once the robots arrive
at the picking area,
303
00:16:41,201 --> 00:16:45,370
Items are readied for customers
who ordered for that day.
304
00:17:02,889 --> 00:17:04,856
The tote heads off again,
305
00:17:04,858 --> 00:17:06,691
This time for
the packing department.
306
00:17:06,693 --> 00:17:10,194
♪♪
307
00:17:10,196 --> 00:17:14,165
But with hundreds of thousands
of items passing back and forth,
308
00:17:14,167 --> 00:17:16,834
What happens
if one goes missing?
309
00:17:16,836 --> 00:17:20,671
♪♪
310
00:17:20,673 --> 00:17:23,741
An alert's gone out saying
there's something on the floor
311
00:17:23,743 --> 00:17:26,444
Which shouldn't be there.
312
00:17:26,446 --> 00:17:29,914
Adam cunliffe is a specially
trained troubleshooter
313
00:17:29,916 --> 00:17:31,649
Who is one of very few people
314
00:17:31,651 --> 00:17:35,753
Authorized to enter the cage
where the robots are.
315
00:17:50,170 --> 00:17:53,104
Adam's jacket is emitting
a radio pulse,
316
00:17:53,106 --> 00:17:56,441
Which tells the robots
to avoid him.
317
00:17:56,443 --> 00:17:58,142
This crucial safety measure,
318
00:17:58,144 --> 00:18:01,546
Protects the automated units,
the merchandise,
319
00:18:01,548 --> 00:18:04,282
And most importantly,
the workforce.
320
00:18:04,284 --> 00:18:06,717
♪♪
321
00:18:06,719 --> 00:18:08,519
With time of the essence,
322
00:18:08,521 --> 00:18:11,722
Adam must find the lost item
as soon as possible.
323
00:18:11,724 --> 00:18:16,360
♪♪
324
00:18:16,362 --> 00:18:18,396
Now that the item is found,
325
00:18:18,398 --> 00:18:23,601
He just needs to retrace
his steps and exit the cage.
326
00:18:31,845 --> 00:18:37,281
♪♪
327
00:18:37,283 --> 00:18:42,520
♪♪
328
00:18:42,522 --> 00:18:44,889
With that mini crisis averted,
329
00:18:44,891 --> 00:18:47,225
The latest batch of items
to be selected
330
00:18:47,227 --> 00:18:52,096
Has reached
the packing department.
331
00:18:52,098 --> 00:18:56,634
Preparing them for dispatch
is a complex process.
332
00:18:56,636 --> 00:18:58,803
But it's designed this way
333
00:18:58,805 --> 00:19:02,874
To preserve
a customer's anonymity.
334
00:19:02,876 --> 00:19:05,510
Here, the item is boxed up
335
00:19:05,512 --> 00:19:10,314
And the first of two labels
is attached.
336
00:19:10,316 --> 00:19:12,917
But this first label
carries only
337
00:19:12,919 --> 00:19:15,653
An impenetrable digital code.
338
00:19:15,655 --> 00:19:19,323
This means that the person
doing the packing has no idea
339
00:19:19,325 --> 00:19:23,928
Who placed the order
or where the package is heading.
340
00:19:23,930 --> 00:19:26,364
It protects the customer's
privacy,
341
00:19:26,366 --> 00:19:29,767
Including the people
who actually work for amazon.
342
00:19:29,769 --> 00:19:32,170
I often get packages
from my own warehouse.
343
00:19:32,172 --> 00:19:33,738
I'm not sure that
I would want anyone
344
00:19:33,740 --> 00:19:35,206
Knowing what I'm ordering.
345
00:19:35,208 --> 00:19:38,042
And the same would go for every
person who's working here.
346
00:19:38,044 --> 00:19:47,752
♪♪
347
00:19:47,754 --> 00:19:50,521
Narrator: The anonymous package
then heads to the machine,
348
00:19:50,523 --> 00:19:53,524
Which will finally print
and apply the label
349
00:19:53,526 --> 00:19:55,760
Carrying the customer's name
and address.
350
00:19:55,762 --> 00:20:01,365
♪♪
351
00:20:01,367 --> 00:20:04,268
That label is printed in
under two seconds
352
00:20:04,270 --> 00:20:06,804
From the moment
the package is rescanned
353
00:20:06,806 --> 00:20:09,907
To when a robot arm descends
and applies the label.
354
00:20:09,909 --> 00:20:13,177
♪♪
355
00:20:13,179 --> 00:20:15,813
The speed of labeling
is incredible,
356
00:20:15,815 --> 00:20:17,148
But it also obscures
357
00:20:17,150 --> 00:20:21,018
One of the most important
details of the process.
358
00:20:21,020 --> 00:20:23,754
Amazon has developed
a critical method
359
00:20:23,756 --> 00:20:26,490
To protect their more
delicate inventory
360
00:20:26,492 --> 00:20:30,695
Without sacrificing efficiency.
361
00:20:32,599 --> 00:20:38,302
♪♪
362
00:20:38,304 --> 00:20:40,571
Narrator:
Amazon undeniably dominates
363
00:20:40,573 --> 00:20:42,707
The online shopping market
364
00:20:42,709 --> 00:20:44,775
With such a high volume
of products
365
00:20:44,777 --> 00:20:47,612
Passing through their massive
fulfillment centers.
366
00:20:47,614 --> 00:20:51,349
The company needed a strategy
to quickly apply shipping labels
367
00:20:51,351 --> 00:20:54,318
Without damaging
fragile merchandise.
368
00:21:13,306 --> 00:21:17,808
The items are now ready to go
to their final destination.
369
00:21:17,810 --> 00:21:20,611
The last conveyor directs them
towards a row of more
370
00:21:20,613 --> 00:21:24,482
Than 100 separate bins.
371
00:21:24,484 --> 00:21:26,851
Each one represents
a different city
372
00:21:26,853 --> 00:21:30,621
Or geographical region.
373
00:21:30,623 --> 00:21:34,125
Now, all the packages are ready
to be loaded onto a truck
374
00:21:34,127 --> 00:21:35,493
For delivery.
375
00:21:35,495 --> 00:21:41,232
♪♪
376
00:21:41,234 --> 00:21:42,767
Across the u.K.,
377
00:21:42,769 --> 00:21:46,070
Fulfillment centers
like this one dispatch packages
378
00:21:46,072 --> 00:21:49,239
To tens of millions
of customers across europe.
379
00:21:49,241 --> 00:21:51,409
♪♪
380
00:21:51,411 --> 00:21:54,011
And with drone delivery
in development,
381
00:21:54,013 --> 00:21:57,948
Amazon continues to secure
its place at the forefront
382
00:21:57,950 --> 00:22:01,018
Of the new
industrial revolution,
383
00:22:01,020 --> 00:22:03,654
The world of robotics
and artificial intelligence
384
00:22:03,656 --> 00:22:05,189
Are undoubtedly merging.
385
00:22:05,191 --> 00:22:07,758
No more will a robot
just be a thing programmed
386
00:22:07,760 --> 00:22:09,927
To perform a specific task,
387
00:22:09,929 --> 00:22:12,263
But actually, it will become
something which learns
388
00:22:12,265 --> 00:22:15,266
From the task it performs,
observes the world around it,
389
00:22:15,268 --> 00:22:18,936
And changes its behavior
accordingly.
390
00:22:18,938 --> 00:22:21,172
Narrator:
Amazon has forever changed
391
00:22:21,174 --> 00:22:25,209
What it means to go shopping.
392
00:22:25,211 --> 00:22:28,979
The revolution ushered in by
super facilities like this one
393
00:22:28,981 --> 00:22:32,650
Shows no sign of slowing down.
394
00:22:32,652 --> 00:22:36,287
♪♪
395
00:22:36,289 --> 00:22:38,823
Much like amazon's fcs,
396
00:22:38,825 --> 00:22:42,827
This slovakian car factory
requires that robots and humans
397
00:22:42,829 --> 00:22:46,230
Work in tandem
to maximize productivity.
398
00:22:46,232 --> 00:22:50,267
♪♪
399
00:22:50,269 --> 00:22:53,871
[ beeping ]
400
00:22:53,873 --> 00:22:57,641
♪♪
401
00:22:57,643 --> 00:22:59,944
Wedged in between
three mountain ranges
402
00:22:59,946 --> 00:23:02,346
And slovakia is jelena,
403
00:23:02,348 --> 00:23:06,050
A picturesque town
with a proud industrial history.
404
00:23:06,052 --> 00:23:09,553
♪♪
405
00:23:09,555 --> 00:23:13,624
Now it's home to
a 40.3 acre super factory
406
00:23:13,626 --> 00:23:16,560
That can make up
to 63 cars an hour
407
00:23:16,562 --> 00:23:21,165
And produce eight models
on the same production line.
408
00:23:21,167 --> 00:23:27,037
This is the european hub
for south korean car giant kia.
409
00:23:27,039 --> 00:23:29,106
♪♪
410
00:23:29,108 --> 00:23:31,375
Established in 2004,
411
00:23:31,377 --> 00:23:36,514
This plant can build
350,000 cars a year.
412
00:23:36,516 --> 00:23:40,818
Rows of robots work in tandem
with 3,800 workers
413
00:23:40,820 --> 00:23:44,889
To produce the ceed, venga,
and sportage models,
414
00:23:44,891 --> 00:23:50,261
Which are exported
to 95 countries worldwide.
415
00:23:50,263 --> 00:23:52,396
Once the underdog of the car
industry,
416
00:23:52,398 --> 00:23:53,998
Once they teamed up
with hyundai,
417
00:23:54,000 --> 00:23:56,600
They became the fourth biggest
car manufacturer in the world
418
00:23:56,602 --> 00:23:59,937
After volkswagen, toyota,
and general motors.
419
00:23:59,939 --> 00:24:05,142
Narrator: It all starts here
with 18-ton giant rolls of steel
420
00:24:05,144 --> 00:24:10,281
And two 5,952-ton presses.
421
00:24:10,283 --> 00:24:12,950
The outer skin panels
are different shapes,
422
00:24:12,952 --> 00:24:16,454
Punched out of sheet steel
called blanks.
423
00:24:16,456 --> 00:24:20,624
The blanking line produces
53 of them a minute,
424
00:24:20,626 --> 00:24:23,427
With so many cars
being made a year,
425
00:24:23,429 --> 00:24:26,163
The choice of metal is key.
426
00:24:26,165 --> 00:24:28,499
Right now,
steel is plentiful and cheap,
427
00:24:28,501 --> 00:24:30,801
Which makes it the ideal choice
for car bodies
428
00:24:30,803 --> 00:24:32,102
Produced by the millions.
429
00:24:32,104 --> 00:24:34,205
Aluminum is lighter
430
00:24:34,207 --> 00:24:36,407
And has a similar strength
to weight ratio,
431
00:24:36,409 --> 00:24:39,043
But it's significantly
more expensive.
432
00:24:39,045 --> 00:24:43,214
In fact,
four times more expensive.
433
00:24:43,216 --> 00:24:46,283
Narrator: The steel blanks are
then sent to the stamping line
434
00:24:46,285 --> 00:24:48,285
To become panels.
435
00:24:48,287 --> 00:24:52,389
Here, they use a method
called cold stamping.
436
00:24:52,391 --> 00:24:55,659
The metal sheets are turned
into the desired form
437
00:24:55,661 --> 00:24:59,830
Using intense pressure
rather than heat.
438
00:24:59,832 --> 00:25:01,499
The robotic presses stamp
439
00:25:01,501 --> 00:25:04,101
1,500 panels each shift.
440
00:25:04,103 --> 00:25:07,571
♪♪
441
00:25:07,573 --> 00:25:12,309
Doors, roofs, hoods, and bumpers
are all stamped here
442
00:25:12,311 --> 00:25:17,181
With robots moving
and transporting the parts.
443
00:25:17,183 --> 00:25:20,150
The factory operates
around the clock
444
00:25:20,152 --> 00:25:23,521
And is able to make
1,450 cars a day.
445
00:25:23,523 --> 00:25:29,260
♪♪
446
00:25:29,262 --> 00:25:33,397
The panels are cut, but even
robots can make mistakes,
447
00:25:33,399 --> 00:25:36,734
So the human eye is brought in
to double check the panels.
448
00:25:36,736 --> 00:25:39,103
♪♪
449
00:25:39,105 --> 00:25:41,505
Any surface defects
will create a problem
450
00:25:41,507 --> 00:25:43,374
When the car is painted.
451
00:25:43,376 --> 00:25:48,178
So being thorough is key.
452
00:25:48,180 --> 00:25:51,415
Once the check is complete,
an electric monorail
453
00:25:51,417 --> 00:25:55,052
Takes the panels to a vast
two-story hangar area.
454
00:25:55,054 --> 00:25:57,821
♪♪
455
00:25:57,823 --> 00:25:59,356
This automated warehouse
456
00:25:59,358 --> 00:26:04,595
Has a capacity
of 6,850 pieces.
457
00:26:04,597 --> 00:26:07,865
The parts are retrieved
on demand.
458
00:26:07,867 --> 00:26:10,334
It's called the just-in-time
philosophy that was developed
459
00:26:10,336 --> 00:26:13,671
By car manufacturers
in japan in the 1970s.
460
00:26:13,673 --> 00:26:16,840
Just in time is about receiving
goods in within minutes
461
00:26:16,842 --> 00:26:19,576
Of requiring it,
assembling the products,
462
00:26:19,578 --> 00:26:21,345
And moving us out
very quickly, too.
463
00:26:21,347 --> 00:26:23,380
This eliminates stock,
464
00:26:23,382 --> 00:26:25,883
It saves money, reduces waste,
465
00:26:25,885 --> 00:26:29,453
And it really drives efficiency
within the plant.
466
00:26:29,455 --> 00:26:32,289
Narrator: But the robots in this
super factory aren't limited
467
00:26:32,291 --> 00:26:35,125
To cutting
and distributing parts.
468
00:26:35,127 --> 00:26:37,361
Kia has also incorporated them
469
00:26:37,363 --> 00:26:40,664
Into the assembly
process itself,
470
00:26:51,777 --> 00:26:56,914
♪♪
471
00:26:56,916 --> 00:26:59,950
Narrator: Once the newly minted
steel panels are quality checked
472
00:26:59,952 --> 00:27:03,954
By a human eye,
kia's robots step in again.
473
00:27:03,956 --> 00:27:06,090
♪♪
474
00:27:06,092 --> 00:27:09,126
They select and transport
panels to the welding shop.
475
00:27:09,128 --> 00:27:14,231
Here, welders will make
the mainframe.
476
00:27:14,233 --> 00:27:15,799
Over the past 30 to 40 years,
477
00:27:15,801 --> 00:27:18,435
Car welding robots have
transformed
478
00:27:18,437 --> 00:27:20,738
The automotive industry.
479
00:27:20,740 --> 00:27:23,207
They are very, very good
at doing multiple
480
00:27:23,209 --> 00:27:24,875
And repeatable tasks.
481
00:27:24,877 --> 00:27:28,479
Robots can also work efficiently
in hazardous conditions
482
00:27:28,481 --> 00:27:31,181
In environments
such as an automotive paint shop
483
00:27:31,183 --> 00:27:34,118
Where chemicals,
structures, and heat
484
00:27:34,120 --> 00:27:35,953
Would be either intolerable
485
00:27:35,955 --> 00:27:39,757
Or potentially dangerous
to humans.
486
00:27:39,759 --> 00:27:42,126
Narrator: There are more than
3,000 welding points
487
00:27:42,128 --> 00:27:44,628
On the body,
488
00:27:44,630 --> 00:27:48,332
374 robots
work in synchronicity
489
00:27:48,334 --> 00:27:52,102
At 40 stations.
490
00:27:52,104 --> 00:27:55,472
The robots weld
using diode disc lasers,
491
00:27:55,474 --> 00:27:58,542
Which are small,
light energy efficient systems
492
00:27:58,544 --> 00:28:00,611
Compared
to conventional welders.
493
00:28:00,613 --> 00:28:03,647
♪♪
494
00:28:03,649 --> 00:28:07,117
The robots can reach hard
to access spaces quickly
495
00:28:07,119 --> 00:28:09,753
And weld
with pinpoint accuracy.
496
00:28:09,755 --> 00:28:15,359
♪♪
497
00:28:15,361 --> 00:28:18,662
The mainframe is almost
complete and the humans
498
00:28:18,664 --> 00:28:22,900
Are again
required to do visual checking.
499
00:28:22,902 --> 00:28:26,336
One car
is checked every minute.
500
00:28:36,982 --> 00:28:38,816
From the body shop,
501
00:28:38,818 --> 00:28:41,552
The car frames are moved
into the paint shop
502
00:28:41,554 --> 00:28:43,487
Via a conveyor system
503
00:28:43,489 --> 00:28:47,791
With a total length
of 4.8 miles.
504
00:28:47,793 --> 00:28:51,662
The paint shop is
a highly specialized dip tank,
505
00:28:51,664 --> 00:28:55,399
Rotating the car 360 degrees.
506
00:28:55,401 --> 00:28:58,335
Bodies are rotated
through a forward somersault
507
00:28:58,337 --> 00:29:00,704
While immersed in the tank.
508
00:29:00,706 --> 00:29:04,575
This ensures the crucial rust
preventative primer paint
509
00:29:04,577 --> 00:29:08,278
Gets into all
the small crevices of the car.
510
00:29:08,280 --> 00:29:12,216
An army of more than
80 painting robots moves in,
511
00:29:12,218 --> 00:29:14,685
Spraying with speed
and accuracy.
512
00:29:14,687 --> 00:29:19,323
♪♪
513
00:29:19,325 --> 00:29:23,327
Now it's time to assemble
the car's internal components.
514
00:29:23,329 --> 00:29:27,030
This area
is much less automated.
515
00:29:27,032 --> 00:29:31,401
More than 1,400 employees work
in the assembly shop.
516
00:29:31,403 --> 00:29:33,570
In this super factory,
517
00:29:33,572 --> 00:29:38,008
The hall is nearly
1,640 feet long,
518
00:29:38,010 --> 00:29:42,346
Totaling nearly
1.1 million square feet.
519
00:29:42,348 --> 00:29:44,314
♪♪
520
00:29:44,316 --> 00:29:48,385
First, the doors are removed
for easier access.
521
00:29:48,387 --> 00:29:50,888
♪♪
522
00:29:50,890 --> 00:29:53,190
Then the assembly starts,
523
00:29:53,192 --> 00:29:56,960
Wiring, pedals,
and interior trim,
524
00:29:56,962 --> 00:29:59,329
Ending with the cockpit.
525
00:29:59,331 --> 00:30:03,534
This is another step
requiring robotic precision.
526
00:30:03,536 --> 00:30:05,636
They've been programmed
to fit this part
527
00:30:05,638 --> 00:30:08,939
With pinpoint accuracy.
528
00:30:25,791 --> 00:30:30,327
♪♪
529
00:30:30,329 --> 00:30:34,198
Next is the crucial marriage
between engine and drive train.
530
00:30:34,200 --> 00:30:37,367
♪♪
531
00:30:37,369 --> 00:30:40,304
It's too intricate
for robots to handle.
532
00:30:40,306 --> 00:30:43,774
So the assembly team oversees
this important step.
533
00:30:55,154 --> 00:30:57,120
This assembly line
has the ability
534
00:30:57,122 --> 00:31:01,825
To produce multiple car designs
on the same line,
535
00:31:01,827 --> 00:31:03,660
Eight different models,
536
00:31:03,662 --> 00:31:08,799
Including the sportage and four
styles of c can be built.
537
00:31:08,801 --> 00:31:12,169
Computers are programmed
with multiple different models.
538
00:31:12,171 --> 00:31:15,372
So it's possible to change
equipment configurations
539
00:31:15,374 --> 00:31:17,374
By selecting different settings
540
00:31:17,376 --> 00:31:19,576
On the computer controlled
machines.
541
00:31:30,689 --> 00:31:33,557
The assembly line reaches
its final stages
542
00:31:33,559 --> 00:31:35,692
With four final lines
of interior
543
00:31:35,694 --> 00:31:39,997
And exterior fittings,
bumpers, and doors,
544
00:31:39,999 --> 00:31:42,699
A robot moves in
with the windshield.
545
00:31:42,701 --> 00:31:46,136
It receives data telling it
which car it's working on
546
00:31:46,138 --> 00:31:48,138
And makes the adjustment
for this model.
547
00:31:48,140 --> 00:31:51,375
♪♪
548
00:31:51,377 --> 00:31:53,944
The car is now assembled.
549
00:31:53,946 --> 00:31:55,612
[ horn honks ]
550
00:31:55,614 --> 00:31:58,382
♪♪
551
00:31:58,384 --> 00:32:00,317
Now it's time for testing,
552
00:32:00,319 --> 00:32:04,588
Using a mix of machines
and extensive driving.
553
00:32:04,590 --> 00:32:07,524
♪♪
554
00:32:07,526 --> 00:32:11,495
The whole process has taken
just 14 hours.
555
00:32:11,497 --> 00:32:13,330
♪♪
556
00:32:13,332 --> 00:32:15,766
This plant has helped
establish kia
557
00:32:15,768 --> 00:32:19,336
Has the fourth largest
car maker in the world.
558
00:32:19,338 --> 00:32:20,737
In the future,
559
00:32:20,739 --> 00:32:23,106
This slovakian super factory
should be
560
00:32:23,108 --> 00:32:27,778
At the forefront of motor
manufacturing for years to come.
561
00:32:27,780 --> 00:32:32,115
♪♪
562
00:32:32,117 --> 00:32:34,351
Coming up,
there's one product
563
00:32:34,353 --> 00:32:37,921
Which the modern world
simply can't live without.
564
00:32:37,923 --> 00:32:41,024
Whether you're building
a laptop, a skyscraper,
565
00:32:41,026 --> 00:32:43,093
Or anything in between,
566
00:32:43,095 --> 00:32:47,130
You're going to need
this versatile alloy.
567
00:32:49,068 --> 00:32:53,804
♪♪
568
00:32:53,806 --> 00:32:57,240
Narrator: In gwangyang,
on the coast of south korea
569
00:32:57,242 --> 00:33:01,445
Lies the biggest steel plant
in the world.
570
00:33:01,447 --> 00:33:04,748
Here, workers go above
and beyond to meet
571
00:33:04,750 --> 00:33:08,618
The insatiable demand
for steel.
572
00:33:08,620 --> 00:33:12,089
It's the world's
biggest steel plant.
573
00:33:25,938 --> 00:33:29,373
This plant turns out roughly
21 million tons
574
00:33:29,375 --> 00:33:32,342
Of steel every year.
575
00:33:32,344 --> 00:33:37,948
That is enough to make around
12 million cars annually.
576
00:33:37,950 --> 00:33:39,649
Steel is
one of those materials
577
00:33:39,651 --> 00:33:41,651
That really defines
our modern age.
578
00:33:41,653 --> 00:33:44,287
There was a moment before steel,
after steel,
579
00:33:44,289 --> 00:33:46,456
And the industrial revolution
is on that line.
580
00:33:46,458 --> 00:33:49,092
When we started to make
a material that enabled us
581
00:33:49,094 --> 00:33:53,163
To make things
that changed the world.
582
00:33:53,165 --> 00:33:56,600
Narrator: The biggest advance in
steel production in recent years
583
00:33:56,602 --> 00:33:59,669
Has been the degree
of automation,
584
00:33:59,671 --> 00:34:03,607
The pohang iron
and steel company, or posco,
585
00:34:03,609 --> 00:34:08,578
Is one of the most
highly automated plants of all.
586
00:34:08,580 --> 00:34:10,013
All around the world,
587
00:34:10,015 --> 00:34:13,016
While the production of steel
has increased significantly,
588
00:34:13,018 --> 00:34:15,852
The number of steel workers
has fallen drastically
589
00:34:15,854 --> 00:34:19,056
By about 1.5 million
people over 25 years.
590
00:34:19,058 --> 00:34:20,924
♪♪
591
00:34:20,926 --> 00:34:23,593
Narrator: Even with the decrease
in workforce,
592
00:34:23,595 --> 00:34:26,897
The factory still requires
a vast site,
593
00:34:26,899 --> 00:34:29,966
Including 50 smaller
sub factories,
594
00:34:29,968 --> 00:34:34,938
Each with a specific role
in the production process.
595
00:34:34,940 --> 00:34:39,309
In order to make steel,
you need two raw ingredients --
596
00:34:39,311 --> 00:34:43,547
Iron ore and coal.
597
00:34:43,549 --> 00:34:46,850
It all starts underground
in australia,
598
00:34:46,852 --> 00:34:49,619
Where iron ore is blasted
out of the ground
599
00:34:49,621 --> 00:34:54,291
From mineral rich land.
600
00:34:54,293 --> 00:34:55,892
Once blasted,
601
00:34:55,894 --> 00:35:00,063
It arrives by ship
to this steel plant's port,
602
00:35:00,065 --> 00:35:02,399
So to take iron
and turn it into steel,
603
00:35:02,401 --> 00:35:03,900
You need to add carbon.
604
00:35:03,902 --> 00:35:06,069
And what happens is the carbon
atoms are actually
605
00:35:06,071 --> 00:35:09,706
Getting inside the crystal
lattice work of the iron
606
00:35:09,708 --> 00:35:13,910
And plumping out these crystals
and turning them from just iron
607
00:35:13,912 --> 00:35:17,547
Into an alloy of iron
and carbon, which we call steel.
608
00:35:17,549 --> 00:35:20,650
♪♪
609
00:35:20,652 --> 00:35:22,986
Narrator: The iron ore at this
early stage
610
00:35:22,988 --> 00:35:26,123
Resembles a kind of gray dust,
611
00:35:26,125 --> 00:35:28,358
Extracting the usable metal
from this
612
00:35:28,360 --> 00:35:31,795
Is a multi-step process.
613
00:35:31,797 --> 00:35:36,066
The technical term for the first
process is called sintering.
614
00:35:36,068 --> 00:35:38,835
♪♪
615
00:35:38,837 --> 00:35:40,937
The iron ore is roasted,
616
00:35:40,939 --> 00:35:44,107
Removing excess sulfur
and other impurities,
617
00:35:44,109 --> 00:35:47,577
Causing what was once dust
to bind together
618
00:35:47,579 --> 00:35:50,347
Into pea-sized nodules.
619
00:35:50,349 --> 00:35:51,982
After sintering,
620
00:35:51,984 --> 00:35:55,519
The ore looks
almost like a sea of baked mud.
621
00:35:55,521 --> 00:35:59,089
♪♪
622
00:35:59,091 --> 00:36:02,792
Next, the ore is mixed
with purified coal
623
00:36:02,794 --> 00:36:06,563
Inside one of posco's
five giant blast furnaces.
624
00:36:06,565 --> 00:36:08,532
♪♪
625
00:36:08,534 --> 00:36:10,500
Blast furnace number one,
626
00:36:10,502 --> 00:36:13,904
Measuring in a 361 feet tall
627
00:36:13,906 --> 00:36:16,706
And 66 feet across
628
00:36:16,708 --> 00:36:20,277
Is the pride and joy
of gwangyang steel makers.
629
00:36:20,279 --> 00:36:22,345
♪♪
630
00:36:40,699 --> 00:36:44,000
To make steel,
carbon is needed,
631
00:36:44,002 --> 00:36:48,405
The primary source of carbon
is coal, which is coked.
632
00:36:48,407 --> 00:36:50,774
Coke is a modified form
of coal.
633
00:36:50,776 --> 00:36:53,610
Essentially coking
is taking coal
634
00:36:53,612 --> 00:36:56,379
And heating it around
a 1,000 degrees celsius
635
00:36:56,381 --> 00:36:59,149
And then holding it there
for a good 24 hours,
636
00:36:59,151 --> 00:37:00,784
Even longer period of time.
637
00:37:00,786 --> 00:37:04,154
And what's happening is you're
essentially purifying the coal,
638
00:37:04,156 --> 00:37:05,855
You're burning off impurities
639
00:37:05,857 --> 00:37:08,525
And you're reducing it down
to pure carbon.
640
00:37:08,527 --> 00:37:11,728
So lumps of coke
are pure nuggets of carbon.
641
00:37:11,730 --> 00:37:13,797
♪♪
642
00:37:13,799 --> 00:37:16,967
Narrator: This high grade coke
will both fuel the fire
643
00:37:16,969 --> 00:37:22,339
Inside the blast furnace
and make steel.
644
00:37:22,341 --> 00:37:26,810
But how does purified coal
and purified iron come together
645
00:37:26,812 --> 00:37:30,714
To make one of the world's
most durable alloys?
646
00:37:30,716 --> 00:37:34,717
The posco team relies
on a complex chemical reaction
647
00:37:34,719 --> 00:37:37,787
And a lot of heat
to keep this super factory
648
00:37:37,789 --> 00:37:41,424
Churning out quality steel.
649
00:37:43,395 --> 00:37:48,231
♪♪
650
00:37:48,233 --> 00:37:51,635
Narrator: In south korea,
but super factory posco
651
00:37:51,637 --> 00:37:56,139
Is one of the world's
most important steel suppliers.
652
00:37:56,141 --> 00:38:00,143
After iron ore and coal
have been purified using heat,
653
00:38:00,145 --> 00:38:01,845
The refined iron and carbon
654
00:38:01,847 --> 00:38:05,248
Are combined
in an enormous blast furnace
655
00:38:05,250 --> 00:38:10,020
To burn off remaining oxygen
and produce molten metal.
656
00:38:10,022 --> 00:38:11,621
♪♪
657
00:38:11,623 --> 00:38:15,058
Layers of ore and coke
are poured into the furnace
658
00:38:15,060 --> 00:38:18,228
To ensure a good distribution
of both.
659
00:38:18,230 --> 00:38:20,463
From below, hot air
660
00:38:20,465 --> 00:38:23,700
At 2,732 fahrenheit
661
00:38:23,702 --> 00:38:26,903
Is injected through nozzles.
662
00:38:26,905 --> 00:38:28,204
Laughlin:
You have to smelt it.
663
00:38:28,206 --> 00:38:31,141
You have to extract the oxygen
out from the iron.
664
00:38:31,143 --> 00:38:33,209
And you do that
by burning it with coke
665
00:38:33,211 --> 00:38:36,146
And you rip the oxygen away,
bonds with carbon,
666
00:38:36,148 --> 00:38:37,580
Goes up into the atmosphere.
667
00:38:37,582 --> 00:38:40,917
You're then left with the iron.
668
00:38:40,919 --> 00:38:43,153
Narrator: At the base
of the blast furnace,
669
00:38:43,155 --> 00:38:46,089
This iron then turns
into molten metal
670
00:38:46,091 --> 00:38:49,726
Due to extremely high
temperature.
671
00:38:49,728 --> 00:38:53,830
But it can't yet
be called steam.
672
00:38:53,832 --> 00:38:55,198
The liquid iron is then
673
00:38:55,200 --> 00:38:58,902
Poured into a torpedo
shaped transporter,
674
00:38:58,904 --> 00:39:02,706
Which will then take the molten
metal to a second furnace,
675
00:39:02,708 --> 00:39:06,042
Also known as a converter.
676
00:39:06,044 --> 00:39:09,946
It's there that the process
of converting iron to steel
677
00:39:09,948 --> 00:39:14,150
Will actually take place.
678
00:39:14,152 --> 00:39:17,821
Once there, the liquid iron
is poured in.
679
00:39:17,823 --> 00:39:20,924
Scrap, steel, and oxygen
are then added to the mix.
680
00:39:20,926 --> 00:39:24,994
♪♪
681
00:39:24,996 --> 00:39:27,564
This process makes
the impurities float
682
00:39:27,566 --> 00:39:30,066
To the top
where they're remove,
683
00:39:30,068 --> 00:39:35,739
Leaving us with
the final product -- steel.
684
00:39:35,741 --> 00:39:37,073
It's essential that
the temperature
685
00:39:37,075 --> 00:39:39,976
During conversion
is precisely regulated
686
00:39:39,978 --> 00:39:42,345
Or the steel
will lose its strength
687
00:39:42,347 --> 00:39:45,715
And durability.
688
00:39:45,717 --> 00:39:47,517
At gwangyang,
689
00:39:47,519 --> 00:39:50,420
The computerized control room
keeps the huge fire
690
00:39:50,422 --> 00:39:53,623
In check with high tech heat
monitoring.
691
00:40:11,209 --> 00:40:16,212
Once purified, the molten steel
is then poured into molds,
692
00:40:16,214 --> 00:40:20,917
Which are then cooled into
a solid semi-finished state
693
00:40:20,919 --> 00:40:22,352
Called a slab.
694
00:40:22,354 --> 00:40:26,423
♪♪
695
00:40:26,425 --> 00:40:30,193
The slab can now be made
into finished steel products
696
00:40:30,195 --> 00:40:34,264
By a process called
hot rolling.
697
00:40:34,266 --> 00:40:41,571
♪♪
698
00:40:41,573 --> 00:40:43,940
With thousands of tons
of pressure,
699
00:40:43,942 --> 00:40:47,877
These rollers squeeze the red
hot steel like a rolling pin,
700
00:40:47,879 --> 00:40:50,613
Pressing on a soft pastry,
701
00:40:50,615 --> 00:40:52,982
Turning it into sheet steel.
702
00:40:52,984 --> 00:40:57,921
♪♪
703
00:40:57,923 --> 00:41:00,256
Now it's ready to be used
in industries
704
00:41:00,258 --> 00:41:03,893
Such as car making,
shipbuilding, or construction.
705
00:41:03,895 --> 00:41:06,629
♪♪
706
00:41:06,631 --> 00:41:10,500
The steel being produced here
is rolled steel,
707
00:41:10,502 --> 00:41:13,336
But it can be produced
to different strengths.
708
00:41:13,338 --> 00:41:14,871
So, for example, like food can
709
00:41:14,873 --> 00:41:16,873
And it's relatively strong
and lightweight,
710
00:41:16,875 --> 00:41:19,175
But actually you could still
crush them with your bare hand
711
00:41:19,177 --> 00:41:20,477
Once the lid's off.
712
00:41:20,479 --> 00:41:23,246
And you compare that
to an object like scissors
713
00:41:23,248 --> 00:41:25,215
That are made out of
a high carbon steel
714
00:41:25,217 --> 00:41:26,749
That actually is really hard
715
00:41:26,751 --> 00:41:29,986
And will hold an edge and will
make a great blade from.
716
00:41:29,988 --> 00:41:31,521
It's the same material family,
717
00:41:31,523 --> 00:41:35,258
But it's actually
very different stuff.
718
00:41:35,260 --> 00:41:38,127
Narrator: The gwangyang plant
is one of those facilities
719
00:41:38,129 --> 00:41:41,164
Which operates largely
in the background,
720
00:41:41,166 --> 00:41:42,665
But without it,
721
00:41:42,667 --> 00:41:47,370
The world would be
a very different place.
722
00:41:47,372 --> 00:41:49,439
Every 24 hours,
723
00:41:49,441 --> 00:41:54,577
Posco produces enough steel
to make 80,000 brand-new cars,
724
00:41:54,579 --> 00:41:57,680
Making this giant steel plant
725
00:41:57,682 --> 00:42:01,784
An undisputed
global super factory.
726
00:42:01,786 --> 00:42:04,053
♪♪
63438
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