All language subtitles for The.Mightiest.S02E06.Big.Machine.Networks.1080p.AMZN.WEB-DL.DDP5.1.H.264-Kitsune_track4_[eng]

Forged in fire
and cast in steel...

It's big, it's huge,
it's intimidating.

...giant metal
machines are engineered to make

human efforts
at work and play easier.

It's like a monster.

Metal touches every
aspect of human life,

from trains
and ships to factories.

It is a part of building
bigger and better technology

to keep our world turning.

London, England
is home to the oldest

and one of the largest
subway systems in the world...

...the London Underground.

We are now one in every
ten journeys in the UK.

Millions
of tons of metal twisted

into an intricate
labyrinth of rails.

- It's like a monster.
-Hundreds of trains,

seemingly endless
amounts of track

and a multitude of stations.

WOMAN (Recorded:) This is an
Elizabeth line service

to Sheffield.

Moving over 1.3
billion riders each year.

It's about six million
customer journeys a day,

so it's a busy, busy network.

Transporting people
seamlessly beneath the city.

No separate access available at
Harrow on the Hill station.

Never a dull day here.

But to keep it going...

We're ready to race.

...takes constant
maintenance and repairs.

The London
Underground subway

is this giant machine.
It's a huge network of tracks

moving incredible amounts of
people every minute of the day.

WOMAN (Recorded:) The next
station is Liverpool Street.

But this 400-kilometre system

comes from humble beginnings.

The London Underground is old,
and to put it in perspective

of just how old it is,
think of it this way.

The subway system was built
before the automobile,

even before the light bulb.

In fact, Abraham Lincoln was the
President of the United States

when the London Underground

first opened its doors.
That's crazy.

In 1860,
London, England

was the largest
city in the world,

with a population
of over three million,

and nearly a quarter million
people commuted by bus,

rail or on foot each day.

To relieve the congestion,

the trains
were moved underground,

resulting in
the world's first subway.

The London Underground was
first constructed using

the cut-and-cover method,

where a trench was dug
along the streets

and then covered over.

The initial trains were gas-lit

wooden carriages hauled by
steam-powered locomotives.

They burned coal

to heat the water
in a boiler to create steam.

Along with steam,

it created
a ton of air pollution.

To eliminate
the pollution and improve

the overall efficiency and
reliability of the service,

the London Underground
began shifting

to electric power in the 1890s.

And by 1905, the entire
network was electrified,

including the locomotives.

Today, the network

is an integral part
of daily life in London.

So, it's approximately five
million customer journeys a day

on the London
Underground network.

If you look at that for the
whole of the United Kingdom,

that's more than all
of the other mainline

train services combined.

Good afternoon.

This is James at the London
Underground Control Centre

with a network
information broadcast.

The biggest challenge
is keeping the Underground

running smoothly and on time.

Any downtime or delays
can cause a snowball effect

throughout the system.

So, even when things

seem to be running
smoothly on the tracks,

the potential for trouble
is always brewing.

So the only other option we have
is to suspend it so that we can
put a good train at Mill Hill.

Push this one past towards
Mill Hill, so it's there.

We've got a train that's
broken down at this station.

We had two trains
stuck behind it,

which had customers on board.

And now, we're looking at how
we can recover this train.

No set free access available at
Harrow on the Hill station.

This is due to
a customer incident.

Never a dull day here.

Yesterday, we had a person that
wasn't breathing on a train.

We had a CPR ongoing
because of that situation.

We couldn't move
the person from the train,

so the line was suspended.

And when things go wrong,
things build up really quickly.

Woman over PA:
Train out of Platform B

with service to Reading...
Platform B, Reading.

-Prime Whiskey-7-8.

What have you done there?

We've done... shut the doors.

We shift a lot of people,
up to 800,000 people a day.

So, a three-minute delay
down here can be catastrophic.

So, our next station
is Bond Street.

Of the 11 subway lines
in the London Underground,

the Elizabeth Line
is the busiest,

transporting nearly
a million riders

along its 118-kilometre
track every day.

With the introduction
of the Elizabeth Line,

we are now one in every
ten journeys in the UK.

So, we are the most frequently
used train in the UK,

and that's from Scotland,
all the way down to in London.

This system is
the backbone of London Transit.

And it takes
a significant beating.

We're going into the shed

because this train is
due planned maintenance.

All that bumping
and grinding on the tracks

results in
a constant flow of repairs

for depots across the city,

like here at Old Oak Common.

Okay, your route should be
coming up shortly for you.

MAN
Thank you.

On a 12-hour shift,

roughly between
midnight and midnight,

we could have
over 100 train moves.

I think it's something like 112
trains arriving and departing.

So, it can get pretty busy.

Each line
of the London Underground

has at least one maintenance
depot to service

and maintain
its trains overnight.

There are 14 depots
throughout the system

to address the variety of
challenges that come

with such heavy use.

So, this is old O'Connor depot.

We do all planned preventative
maintenance, which is our exams,

all the way through
to corrective repairs.

So, this is the sole location

to maintain the Class 345
Elizabeth Line fleet.

It all starts

with the Automatic Vehicle
Inspection System,

or AVIS for short.

As the train rolls
into the depot,

the AVIS uses special cameras,
lasers, and thermal imaging

to scan every component
of its structure,

from the roof and body, to the
wheels, brakes, and axles.

It collects data on the
condition of the components,

anticipating problems
before they occur.

Once the train has
cleared the system,

AVIS details
the repairs needed,

optimizing maintenance.

AVIS is like a doctor
scanning your entire body

and doing every test

all at once
to see how healthy you are.

So, you can see AVIS building
has now illuminated.

So, this section here we're
coming into takes photographs

of the outside of the trains.

There are two
AVIS sheds, with washers,

processing 35 trains per day -

half of the
Elizabeth Line fleet.

They allow the team to stay on
top of maintenance and address

potential issues before
they lead to breakdowns.

But the AVIS
doesn't stop there.

And the lasers below,

they'll be measuring
the brake pad thickness.

Getting this kind of intricate
report helps maintenance crews

to plan out repairs that are
needed for the fleet super fast.

Before the AVIS,

a train would be
manually inspected

once every month.

But now,
maintenance technicians scan

and even wash the train
in about five minutes.

It's done every time
a train comes back onto depot.

They go through AVIS
and the wash.

So, every 48 hours, roughly, we
get every train back to depot.

However, not
everything is a quick fix.

When there's more significant
damage or maintenance is needed,

it calls for major overhauls.

The Elizabeth Line
is the busiest

of all the
London Underground lines.

Collectively,
trains on this line

travel over
32,000 kilometres a day.

That causes a lot of
wear on the trains,

especially on the bogies.

Bogies are sets of four wheels

attached to each axle
of the train car.

When these bogies travel along
the twists and turns

of the tracks, the outside
wheels wear differently

than the ones on the inside.

That uneven wearing
can cause big problems.

So, like rotating
the tires on a car,

these wheels have to be moved
to different positions, too.

MAN
Have my permission

to pass the stockyards and enter
the shed on line 9.

- Understood.

So, we're coming into Road 9,
Maintenance Road 9.

This road is
specifically designed

to be able to lift
this train up into the air.

This track leads to
the synchronized jacking system,

where 36 high-pressure
hydraulic cylinders lift

all nine cars of
the 200-meter-long train,

giving maintenance workers
access to the bogies.

About 50 meters to go still.

Changing the position
of the wheels is a major job,

which starts by lining up
the trains anchor points

with the jacks.

MAN
Okay, slow down, James.

Five, four, three,

two, go in.

Lovely.

Lovely.

So, we're just putting in the
last jack to move up the train.

Okay, we're ready to race.

JAMES
Yeah, in position.

Okay, going
to start lifting now.

Each hydraulic jack is connected

to a central
computer-controlled unit

that ensures all the jacks are
synchronized while lifting

or lowering the train.

Lift complete.

The next step is to rotate

the bogies as fast
and as safely as possible.

Enter the bogie drop -

a custom-made system

that carries bogies
down through the floor,

along a conveyor, and
back up to the waiting train.

Today, we're rolling
the bogie onto the bogie drop.

From a bogie workshop, we're
going to be dropping it down

and round onto a Mike-7, ready
to fit to another train.

If my leading axle or wheelset
has hit, you know, a tree branch

or something like that and it's
made the wheelset defective,

we can utilise the bogie drop
to replace that wheelset

within maybe an hour.

Going to drop down
to the bottom of the bogie drop.

Going to traverse across
around 30-40 meters.

So, this is a brand new
system for this depot.

And then, come back up

in line with the rails
in front of that train.

The new Old Oak
Common Depot opened in 2018.

It's a transport super hub,
capable of servicing 70 trains.

We can do maintenance

in a lot more timely fashion...

...than other depots
that are older

because we have the better
equipment on our site,

which is really good.

Just as important as the trains,

the tracks also need
continuous upkeep

due to the relentless
pounding they take.

The fact of the
passenger trains going over

just constantly,
literally just grinding down

the profile
of the track, normally,

it happens more over to one side
if you're on a corner,

where the train will ride up

and it will take out the curve
of the rail over constant use.

Back in the old
days of the Underground,

when it first opened, the
workers had to walk the tracks

and visually inspect the rails
to check for any damage.

The workers used hammers
to strike the rails

and listen for unusual sounds,

and then use the manual
grinding or filing tools

to remove all
the surface irregularities.

Or even worse, having to
cut out the defective part

and weld in
a new section by hand.

But today,

it's a much more technologically
advanced endeavour.

When the London Underground
shuts down for the night

and the city goes to sleep,

the work of the rail milling
train begins.

- Okay, on the move.

So, we always mill overnight.
We don't mill during the day.

Otherwise, it can disrupt
the passenger train services.

Before the rail
milling train can get started,

a series of safety checks
must be completed.

TPWS and AWS operational.

So, it's now in work mode

and Marcin can test out

all the equipment's
working as it should be.

And we'll be able to
operate the milling machine.

- Ready to drop down.

Every night we have to simulate
the operation.

To check the machine is actually
operating as it should before,

because on the shift,
there's not time to fix that.

Right.

Basically we have to ensure that
the machine is faultless.

I'm looking now at
the Eddy current system

to make sure that there's no
springs or anything broken,

all the cylinders are
in the correct places,

making sure there's nothing
physically damaged.

I'm just checking the polishing
unit and the grinding unit.

Sometimes, after constant use,
you get some damages

along the edges there

and up the top there where the
grinder dust is going through.

When the tests are complete,

the rail milling
train gets the okay

from dispatch to head out.

- Okay, releasing the brakes.

But this
incredibly advanced machine

only has a four-hour window

to complete its work
before the subway reopens.

The rail milling train

restores the rails
to their correct profile,

reducing wear on both
the wheels and the tracks.

Okay, grinders
on 62 and 10 speed.

Correct profile means
the cross-section

looks like it should, that if
you looked on it straight on,

it's just the right shape.

Guided by magnets and lasers

that scan the
tracks for problems,

the first task of the
rail milling train

is to smooth out
the rails by shaving them

with metal brushes
and carbide shears,

essentially
cutting out deep wear,

cracks and surface dents.

If you've ever been on a subway

and heard that
screeching sound

during a curve...

...you'll appreciate
the importance

of these grinding units.

So, we've got a total of six
milling heads on our unit here.

They're interchangeable

and on the heads,
you've got rights and lefts,

and it's critical that
they go on the right one.

Otherwise, it will cause
damage to the milling head

and the rail head surface.

We had a batch
of older, like, teeth,

as we call them, which
are on the milling heads.

They were only lasting
400 to 500 meters,

but we've had over a thousand
meters on these new heads,

so they are much better
and much more efficient.

Just let me know when
the radio is on channel three

because the
camera is a bit dark.

Overnight,
alone in the Underground,

the work of this
team is invaluable

for the lives
of millions of riders.

If mistakes are made during
the rail milling process,

it can be catastrophic
for commuters.

Just felt a bit of
jumping there, mate.

Okay.

A bit of the
bogie steering jump.

Just keeping an eye.

I didn't see nothing on
the camera though, mate.

Yeah, if you're not careful when
you do cut the track too deep

or for whatever reason,
depending on the severity

of the damage to the rail,
it could cause derailments.

So, it's really
important, obviously,

you concentrate
on what you're doing.

The London Underground,

like all rail systems,
has a history of derailments.

So, the importance of the
overnight milling train

and maintenance crew

to keep this massive transport
system running smoothly

and safely cannot
be understated.

To make sure that things run
on time and not have accidents,

we need to see where defects are
and identify them for repair.

Next,
the milling train polishes

and buffs the rails,
so they make better contact

with the wheels of the train.

The engineering that's gone
into this machine is unreal.

And it's really-- it's a--

it's a big machine and it's
capable of doing great things.

Yeah, profile's all good, mate.

Longitude's good and
the trans is good as well.

Finally,

with the track
maintenance complete,

the milling train
returns to the depot.

Now that the night has ended and
the sun rises over the city,

the London Underground
is ready to open its gates

and do it all over again.

The London Tube is
the GOAT of transit systems.

It's the reason that we have
subways around the world.

And so, it's so exciting because
it's where the idea came from.

It's the first people to say,

"We should run
trains underground

"and it would make better
transit for our system."

London sets the example
for what you can do

if you build a city connected
to really good transit.

With miles of gleaming rails

and fleets of trains in motion,

it truly is one of the world's
mightiest metal machines.

This is the
Carnival Celebration.

It's more than one of the
world's biggest cruise ships.

This is a self-sustaining
home away from home

for its 6,500 passengers,

transporting them
from port to island port.

It's a floating city.

The Celebration
is a floating oasis,

bringing the comforts
of a city to the open seas.

Coming in at nearly
200,000 tonnes,

this massive steel hull

has 19 decks for guests
and entertainment,

as well as crew
and the many engines,

machines and parts that keep
this cruise on course.

And this travelling paradise
would not be possible

without liquid natural gas -

the lifeblood
of the Celebration.

As the name would imply,
natural gas is a gas.

But it's hard to transport

because it takes up
so much space.

If you take that natural gas

and cool it down really, really,

really cold, it turns
from a gas into a liquid

that can then be transported
anywhere in the world you want.

But a ship this size,
using specialized fuel,

can't just
pull up to the pumps.

The pumps need to pull up to it.

So, this is a barge that
was specially built to carry

liquefied natural gas.

These
purpose-built barges store

and transport the equivalent

of nearly four million
litters of fuel -

enough to refuel
two massive ships

headed for a seven-day cruise.

This ship can hold

approximately
3,500 cubic meters.

It is brought down
to approximately

170 degrees negative Celsius

or around 280 degrees
negative Fahrenheit.

The cryogenic
state of liquid natural gas

is so important for
the storage needs of the ship.

It saves a tremendous
amount of space.

Bridge fire patrol from LNG
station everything is fine.

Once on board, the LNG
is used to power the motors

and generators
that provide energy

for everything necessary

to keep the guests
comfortable in transit.

O-25.

Up above,
it's a vacationer's paradise.

But below deck, it's a
mechanical maze of machines,

cables and pipes that connect
to every component of the ship.

The engine room,

it's all the way from the aft
of the ship to the forward.

Below
the waterline on Deck Zero

is the beating heart
of the Celebration -

the place where all that fuel is
transformed into power

for each of the ship's
operating systems.

This is the motor
and this is the generator.

The difference

between the motor
and the generator

is that the motor
produces mechanical power,

just the movement.

The generator converts the
movement in electrical power.

To power these
four enormous engines,

liquid natural gas is converted
back to its original form - gas.

Inside the engine,

the gaseous fuel
is then mixed with air

and introduced to
a pilot fuel that ignites,

creating combustion.

The resulting pressure
pushes down on the pistons,

creating a powerful movement.

All four generators
power up the network.

Without this, we will
not run anywhere.

The ship is a piece of steel.

With no power, no electricity,
no light, no water, nothing!

When the power is flowing,

it's the ship's state-of-the-art
propulsion system

that keeps this floating oasis
alive and moving on the water.

My name is Vincenzo Alcaras.

I am the captain
of the Carnival Celebration.

This ship is
a little bit different

from any other traditional ship
because it is a pod ship.

Historically,
ships relied on simple tools

to navigate the open waters,

from the sun, moon and stars to
compasses, sails and runners.

But boat steering systems

have undergone
significant modernization,

propelled by
advanced technology,

leading to the introduction

of azimuth pod systems for
cruise ships in the late 1990s.

What you'd expect to see on
a boat is a fixed propeller

and a rudder right behind it.

Now, what the pod does

is move that propeller and the
rudder kind of into one thing.

The propeller itself
will push the ship

in whatever direction
it needs it to go.

Azimuth pods
are a gearless steerable

propulsion system where the
motor is housed within the pod,

outside the ship's hull.

They allow huge ships,
like the Celebration,

to navigate narrow waterways

with the ease of
a much smaller vessel.

This advanced technology

can rotate 360 degrees,
providing unparalleled control

over the ship's
direction and speed.

It's a revolutionary propulsion
system that allows massive ships

to manoeuvre with incredible
precision and efficiency.

Once in open water,
this ship is designed

to be an island unto itself,
responsible for the lives

of every guest and
every crew member on board.

The Carnival Celebration
is a cruise ship

that carries
thousands of people.

As soon as the ship
leaves the dock,

there's no connection to shore.

Even though it's
surrounded by water,

freshwater is the key
to survival at sea.

The earliest European sailors
used barrels laced with alcohol

to keep algae from
growing on their supply.

And the most important task
whenever a ship reached land

was to replenish
its freshwater stock.

In the 1700s, distillers
were introduced to ships

to create freshwater
through evaporation.

And then, in the 1980s,
reverse osmosis systems

were added to desalinate water.

These are our
freshwater generators.

This equipment

is taking water from the sea

and producing freshwater.

Onboard, we are keeping 4,500
cubic meters of water,

which is approximately
1,200,000 gallons,

to supply the water to our ship.

These four water
generators produce enough water

to fill and
maintain the equivalent

of nearly two full Olympic-sized
swimming pools.

The Celebration draws ocean
water into the vessel

that makes its way through
a reverse osmosis system.

There, tubes force the water
through a multi-layered membrane

that allows small water
particles through,

but filters out
salt and impurities.

Then, the resulting
freshwater is re-mineralized

and chlorinated for use

throughout the
network of the ship.

Without this equipment,
we will not have the water

for taking a shower, we will not
have the water for laundry,

for flushing the toilet.

While saltwater
is readily available,

it is a hard mineralized water

that would corrode
and ultimately destroy

the ship's plumbing system.

Those are one of the vital
equipment onboard the ship.

All the water for the
ship is provided by this system

and the freshwater pumps

that send potable water
to every deck, sink, faucet,

and facility.

After solving the problem
of potable water,

engineers got to answer
some more unique questions.

Like, how can a ship
turn water into beer?

I am the brewmaster on the ship.

Everything from grain to glass,

ordering to serving,
all falls on me.

I can control everything

from water flow
to the brewing process.

The soft remineralized
water of the ship is less heavy,

making it ideal for brewing
several styles of beer.

Without that
desalinization process

and without being able
to pull that water in,

we would not be able to make
the beer we make on the ship.

It takes a lot of
water to make beer.

On average,
the brewery makes

1,000 litres of beer a week,

which takes 5,000 litres
of water to accomplish -

a fraction of the freshwater
produced by the ship,

but it's very appreciated.

The only place
you're gonna get this beer

is right here on this ship.

The demand for beer is high,

but nothing beats
the demand for food.

And ferrying from port to port,

packed to the brim
with necessities,

doesn't leave a lot
of room for food waste.

We're working very hard
to reduce food waste

in general from our ships,
because food waste

is a large contributor

to greenhouse gases
around the world.

A ship of
this size can carry around

300 tons of food,
and 30% of that

could be wasted
during a vacation.

In the pursuit of efficiency
and sustainability,

technology is helping
this ship stay on course.

So, in our efforts to
try to reduce food waste

onboard the ships, we're
integrating AI technology,

so that we can actually scan
what is left on the plates

that come back from the tables.

The AI tracks the weight

and food type of the
leftovers to determine

if the culinary team
should change the menu

or portion of food being served.

Hey. How you doing?

It's an
innovative solution,

reducing food waste
and food storage needs.

This is a biodigester.
We take food waste

from around the ship,
and we add beneficial bacteria,

and some bio media,

and the bacteria,
they digest the food waste

that's left on people's plates,

and what comes out
is the water that we use

to just flush the drain.

With a mixture
of microbes and enzymes,

this specialized equipment
digests most food products

and even bio-plastics
within 24 hours.

Our biodigesters are critical
to us because it allows us

to dispose of the
food waste that's on board.

And biodigesters
drastically reduce the need

for incinerators and
bulk waste systems

that take up
valuable deck space.

Behind the scenes,
it's our job to make sure

that we're addressing any kind
of environmental impact.

Through food waste management

and water and waste
recycling systems,

the Celebration,
along with the 29 ships

of the Carnival cruise fleet
divert nearly 9,000 tonnes

of waste materials from
landfills every year.

So, it's important to remember

that this is a floating city

because most resorts aren't
making their own electricity,

they're not generating
their own potable water,

and recycling them,
like we are on board.

The Celebration
is a beacon of efficiency

and innovation,

ushering thousands of people

to and from their dream
vacations annually,

a metal marvel on the high seas.

crui,

to construction machines,

to mining equipment...

...Caterpillar keeps
some of the biggest

vehicles in the world moving.

These machines,
they're a work of art.

They're massive
monster machines.

These mammoth off-road trucks

stand two stories tall.

I mean, I'm big, but this
is real strong right here.

And they're engineered
to haul 363 tonnes of cargo

through some of the toughest
terrain on the planet.

There's nothing
like this that exists.

These trucks are born
in a high-tech factory

in Middle America...

We have the biggest of the big,
right here in Decatur, Illinois.

...where robots and
humans work in harmony

to bring these
behemoths to life.

This is the
start of something big.

These trucks have to be big

to move the
vast amounts of material

needed in modern mining.

Mining trucks are so enormous

that they have to
be built in segments.

For example,

the frame of the 797 truck

starts with nine separate
pieces or castings.

We have some of the most
advanced welding equipment,

machining equipment,

and also assembly equipment
that's on the planet Earth.

The nine castings
will form the backbone

of the Caterpillar
797 haul truck.

They are locked in place
with hydraulic clamps.

These hydraulic clamps
are so strong,

strong enough to hold a 90,000
pound truck in place.

Once the pieces are clamped,

they're ready for tack welding,

which joins
the pieces temporarily.

Then, giant cranes
heft the assembled

40,000-kilogram frames

and lower them into place
on the rollover station.

DR. EL-SAYEGH: The rollover
station is a giant

rotation mechanism,
almost like a rotisserie.

It has enormous hydraulic power

that holds the
tacked frame in place

and can rotate it 360 degrees.

We have nine rollovers

in this one line here
in this building,

and each one of them rotate
45 to 90,000-pound truck

360 degrees, so my operators
can weld on them easier.

It's like buttering
a corn on a cob.

Before rollover
machines brought the workpiece

to the welders, they would have
to kneel, bend, and twist

to reach their welds.

If we did not have
this machine, it would take

a whole lot longer
to weld these frames.

Because how else are we really
gonna be able to flip it around?

Once the welds are in
place, the robots take over.

You have to have big robots
to make these big machines.

The entire concept

behind robots building
other things is so that

they're precise, they're
accurate the entire time,

and they're very predictable.

Each frame has
an individual program,

and it tells the
robots what to do.

So, it follows that program,
and it will come to me

if it needs help, and...

Otherwise, it pretty much knows
how to do its own thing.

Here, robotic arms

manoeuvre with precision
around the frame,

depositing over
17 kilometres of welding wire

along a pre-programmed welding
path for each 797 truck.

So, this is actually what our
welding wire looks like.

This is what we use to
weld the frames together.

So, the weld wire is covered
in a copper coating

to make sure that it doesn't

react to the atmosphere
and that it doesn't rust.

Copper is uniquely durable.

When it's exposed to the air, it
forms a distinctive green patina

that protects it
from further corrosion.

So, the rollers on the back feed
the wire up through this hose,

into these rollers,

that allow the robot to
just feed all the time.

And it keeps
a consistent speed and pace.

This automated system
works continuously for 14 hours

to weld the entire frame.

It would take two skilled
welders 48 hours

to do the same work.

For trucks that are used in
heavy-duty mining environments,

creating a frame that has
structural integrity

and durability is crucial.

Mining trucks need to be able
to work 24 hours a day

in the demanding
setting of a mine,

climbing and
descending steep hills

with hundreds of tons of cargo.

Creating trucks this tough

requires humans and robots
to work side by side.

The robots that are
in their own factories,

working with other robots,
they're just called robots.

But robots that are working
alongside humans

and interacting with
humans using sensors

are called co-bots.

Co-bots depend on
human support to do their jobs.

I change the torch,

I make sure the nozzle is clean,
I check the tip,

check the weld wire, and make
sure that it's good to go.

I'm pretty much
the robot's assistant.

played such a heavy handobos

in the manufacturing process.

The Caterpillar Tractor Company

was formed in 1925,
and at that time,

workers assembled machines
with hand tools.

Large components,
like engine blocks and frames,

were often produced by shaping
metal under high pressure

or casting molten
steel with moulds.

Operators had to be strong
enough to physically crank

handwheels and manipulate
levers on milling,

turning and drilling machines.

- All right.
-All right.

All clear!

In the 21st century,
manufacturing technology

is fabricated for the future,

allowing Caterpillar to make
bigger trucks than ever.

We have a system
of fork trucks,

cranes, and
automatically guided vehicles

that move the components
around this massive campus.

We're going to need
to go a little bit more.

More?

Industrial tugs
effortlessly push

gigantic steel components
along specialized rails

that run the entire
length of the factory.

- Perfect!
-All right.

This tiny thing right here
pushes at least 30,000 pounds.

I'm strong,
but I ain't that strong.

Automatically
guided vehicles or AGVs

navigate autonomously
through the factory,

delivering tools
and parts to operators.

Autonomous systems are perfect
for simple repetitive tasks.

The machine can follow
pre-mapped routes

and programmed activities.

So, the AGV actually
helps us out quite a bit.

It's able to free up
more operators

to be more efficient on their
jobs, not have to worry about

walking across the
building to get their kits,

to walk them back, in order
to get their operations

done in a timely manner.

Cranes,
powerful enough to lift

an assembled 797 chassis,
move components overhead.

These cranes consist of
horizontal beams

spanning the width of
a factory, called bridges,

with movable carriages that
travel along them like trolleys.

We couldn't do anything

in this factory
without these cranes.

Everything weighs too much,

they're too bulky.

Just without them,
nothing would work.

The assembled
and welded frame

is lifted to
the inspection station.

And now, it is time to
ensure the welds can hold up

to the punishment
they'll be facing.

The way to do that

is to look inside the steel
frame with ultrasound.

So, this is
a ultrasonic couplet,

and it allows the ultrasound
to go into the metal,

so that we can do our
ultrasound inspection.

DR. EL-SAYEGH: The factory
checks the integrity

of the welds with
an industrial ultrasound

that is very similar
to a medical ultrasound.

It just works
at a higher frequency.

The ultrasound
scanner emits sound waves

that pass through the frame.

If they encounter
an internal defect,

like cracks
or a gap in the weld,

part of that wave
is reflected back,

showing the operator the depth
and size of any defects.

Without this technology,

we wouldn't have a good view
of the quality of the weld

below the surface.

Every single
frame produced here

must match the engineering
specifications exactly.

So, a handheld 3D scanner

is used to inspect
each completed frame.

This is a MetraSCAN 3D.

It basically scans the part
and makes it a 3D model.

There's cameras
all around this thing,

and you can do a whole 360

or even twist your wrist
and it'll still see the part.

There's nothing
like this that exists.

It's the top of the line.

This machine can quickly

identify any discrepancies

between the 3D model and the
original computer-aided design,

allowing for early
corrections to be made.

I like seeing the 3D model,

and it's very satisfying to
see it get printed on screen.

It's addicting.

The frame is painted

and the truck
begins to take shape.

All right, go ahead
and start up, Jeremy.

Once the steel frame
is solidly locked together...

All right, that's good.

...the other
components of the truck

are lifted
into place with cranes.

It can be intense.
It's big, it's huge,

it's intimidating,
but you get used to it, so...

The mining truck's

nearly 2,000 kilogram radiator

is guided into position.

Keep going on down
when you're ready. Okay.

All right, going down.

- South a little bit.
- South, yep.

- All right, start down.
-Going down.

We just got to watch
these stabilizers here

and make sure it all lines up.

All right, isolators in.

Got it? All right.

Yeah, right in there.

Technicians
systematically attach

each component that makes
this machine functional -

the engine, hydraulic tank,
and the transmission.

Right here, we have the
transmission of the 797.

Here is the 797 engine.

Engine produces
4,000 horsepower.

This kind of power
enables the truck to move

massive amounts of
material very efficiently,

making it an essential
piece of equipment

in industries like mining
and construction,

where transporting huge
quantities of material

is routine.

I love just doing
this stuff, so...

It's really cool.
I mean, it's, like, huge.

And plus, we're the only people
in the world that do this job.

So, it can be kind of
rewarding, I guess. So, yeah.

Once the truck has been tested,

it's finally ready
to be sent to the mine.

This facility has got
unbelievable capabilities.

We can do pretty much
everything to build machines,

and we can handle it
within the walls of Decatur.

This is one mighty factory.

Don't underestimate it.

These machines are
sent all over the world,

ready to move the earth itself.