Original subtitles

Narrator: TODAY ON "HOW IT'S MADE: DREAM CARS"...

GERMANY'S MOST ICONIC SPORTS CAR --

THE PORSCHE 911.

-- Captions by VITAC -- www.vitac.com

CAPTIONS PAID FOR BY DISCOVERY COMMUNICATIONS

THE SIXTH LARGEST CITY IN GERMANY -- STUTTGART --

IS KNOWN AS THE CRADLE OF THE AUTOMOBILE.

HERE, THE PORSCHE FAMILY DESIGNS AND ASSEMBLES

SOME OF THE MOST FAMOUS SPORTS CARS ON THE PLANET.

3,000 EMPLOYEES WORK TO MANUFACTURE

PORSCHE'S MOST CELEBRATED CAR -- THE 911 COUPE.

IN 1963, FERDINAND ALEXANDER PORSCHE

DESIGNED THE ORIGINAL 911 TO BE CALLED THE 901,

BUT THERE WAS A LITTLE COMPETITION --

AN EXISTING MODEL FROM A COMPETING AUTOMAKER

FORCED PORSCHE TO RENAME THE CAR THE 911.

BY 1964, THE PORSCHE 911

WAS THE MOST DYNAMIC SPORTS CAR OF THE PERIOD.

THIS CAR IS THE RESULT OF A LONG HISTORY,

WITH THE CREATION OF THE 1939 TYPE 64 --

A MODEL WITH AN ALL-ALUMINUM CHASSIS

WHOSE FINAL VERSION NEVER EMERGED.

PORSCHE CONSIDERS IT

THE GRANDFATHER OF ALL THEIR CARS.

SINCE THE BEGINNING, THE COMPANY HAS CREATED SPORTS CARS

AND CARS SPECIFICALLY FOR MOTOR SPORTS.

THIS 911 IS THE MOST SOPHISTICATED MODEL EVER BUILT,

WITH FUTURISTIC DESIGN, ADVANCED TECHNOLOGIES,

IMPROVED ENGINE PERFORMANCE, AND A LIGHTWEIGHT BODY.

IT'S A SUPERCAR THAT EPITOMIZES

TRADITION, INNOVATION, AND A RACING PEDIGREE.

THE 911 STARTS WITH THE BODYSHELL ASSEMBLY,

WHERE THE CHASSIS IS MADE WITH MILD STEEL AND ALUMINUM.

PRODUCTION ISLANDS WITH WELD-AND-TRANSFER ROBOTS

PUT TOGETHER THE LARGEST PARTS --

NOTABLY, THE BASE OF THE ENGINE BAY.

THE THREE ROBOTS ARE PROGRAMMED TO WORK ON

ALL VARIANTS OF THE MODEL.

TWO WORKERS VERIFY THE QUALITY OF THE SPOT WELDING.

INSPECTING EACH WELD, THEY EXECUTE NECESSARY CHANGES,

AS WELL AS MEASURE THE DISTANCE BETWEEN THE PARTS.

WHEN THE WORKERS COMPLETE THEIR ASSESSMENT,

ROBOTS MOVE THE PARTS TO ANOTHER WORKSTATION.

THE CAR'S BODYSHELL SIDE PANELS

MOVE VIA A CONVEYOR LIFT TO A WELDING STATION.

A WORKER INSTALLS THE PANELS INTO A SECURE SECTION

WHERE ROBOTS WELD THE PARTS WITH PRECISION.

SINCE THE CAR'S CHASSIS IS A MonoKote STRUCTURE

RATHER THAN A TRADITIONAL CHASSIS,

THE SIDE PANELS ARE ATTACHED WITH THE BASE ALREADY COMPLETE.

AUTOMATED GUIDES HOLD THE PANELS IN PLACE

WHILE THEY ARE WELDED TO THE BASE.

THE BODYSHELL ASSEMBLY LINE DELIVERS THE DOORS,

AND WELD ROBOTS SECURE THEM

BY PRECISELY WELDING THE HINGES TO THE BODY.

HOWEVER, IT'S ONLY TEMPORARY,

SINCE THE DOORS WILL BE TAKEN AWAY AFTER THE PAINTING PROCESS,

ONLY TO BE REATTACHED ON THE VEHICLE ASSEMBLY LINE.

OTHER FRAME PARTS IN THE CAR'S ROOFTOP

ARE WELDED TO THE VEHICLE PLATFORM

IN THIS AUTOMATED ASSEMBLY SECTION.

AN AUTOMATED LIFT MOVES THE SKELETAL BODY OF THE CAR

TO ANOTHER STATION FOR TREATMENT AND INSPECTION.

WORKERS INSPECT THE BODY

AND VERIFY THE STRENGTH AND QUALITY OF THE MACHINED WELDS.

AFTERWARD, THE STRUCTURE IS TAKEN

BY AN OVERHEAD CONVEYOR LIFT

TO ANOTHER ASSEMBLY LINE FOR PARTS AND CLEANING.

AT THIS STAGE, WORKERS INSTALL THE HOOD COVER

AND CARRY OUT MANUAL CLEANING.

USING SOFT CLOTHS AND SPECIAL CLEANING AGENTS,

WORKERS ELIMINATE ANY CONSTRUCTION DUST

ALONG THE BODY'S SURFACE.

THE FRAME, WEIGHING 80 POUNDS LESS

THAN THE PREVIOUS GENERATION'S CHASSIS,

IS MOVED BY A TRANSFER LIFTER TO THE PAINT SHOP.

THE PAINTING PROCESS BEGINS BY DIPPING THE BODY

INTO A BATH OF CATHODIC DIP PRIMER.

CATHODIC PAINT ENHANCES

THE CORROSION RESISTANCE OF THE CAR'S STRUCTURE,

BRINGING THE BODY CLOSER TO AN IMMUNE STATE.

NEXT, A HIGH-PRESSURE SHOWER RINSES THE FRAME

TO REMOVE ANY EXCESS PAINT

BEFORE THE FRAME DIPS INTO THE PRIMER TREATMENT AGAIN.

SEVEN CONSECUTIVE PRIMER BATHS ARE EMPLOYED

TO SHIELD THE CAR'S BODYSHELL FROM RUST

AND OTHER ENVIRONMENTAL DAMAGE.

BY FLIPPING AND RETURNING THE BODY INTO THE BASIN,

THE PRIMER PAINT IS GUARANTEED TO REACH

EVERY CAVITY AND CORNER.

IT ALSO ELIMINATES ANY STREAKS

THAT MIGHT DEVELOP AT INTERSECTIONS.

AFTER THE PAINT IS CURED IN A 30-MINUTE DRYING PROCEDURE,

THE STRUCTURE MOVES INTO ANOTHER ROOM

WHERE PAINT ROBOTS UNDERSEAL WITH SEAM-SEALING PAINT,

WHICH CONSISTS OF A PVC COATING.

THIS LAYER OF PROTECTION WATERPROOFS ALL SEALS

AND ELIMINATES ADDITIONAL POSSIBILITIES OF CORROSION.

IN ANOTHER PAINT ROOM, THE BODY RECEIVES A FILLER COATING.

PAINT ROBOTS APPLY THIS BASE COAT,

WHICH SERVES TO PROTECT THE BODY FROM FLYING STONES.

THE FILLER-COATING COLOR IS SELECTED BY THE CUSTOMER.

ALL PAINT COLORS CAN BE REPRODUCED AT AN ADDED COST.

THE STRUCTURE REQUIRES EIGHT LAYERS

OF THE ENVIRONMENT-FRIENDLY, WATER-BASED FILLER COATING

FOR FULL COVERAGE.

ONCE THE PAINT IS CURED,

THE BODYSHELL MOVES TO ANOTHER AREA

WHERE ROBOTS APPLY TWO SOLVENT-BASED CLEAR COATS

TO PROVIDE PROTECTION AGAINST SCRAPES AND SCRATCHES.

A WORKER WEARING PROTECTIVE GLOVES

TO AVOID ANY CONTACT WITH THE NEW PAINT

INSTALLS THE COMPANY'S CREST ON THE HOOD

WITH A SPECIALLY CRAFTED CLAMP,

REVEALING THE SYMBOL OF STUTTGART'S PRIDE.

Narrator: THE APPEAL OF THE PORSCHE 911 IS THE SILHOUETTE,

BUT THE EXCITEMENT IS FROM A SIX-CYLINDER FLAT ENGINE

PRODUCING 350 HORSEPOWER --

MORE THAN ENOUGH DRIVING FORCE FOR ANY ROAD.

A WORKER DELIVERS PRE-PICKED ENGINE COMPONENTS

SUCH AS THE CRANKCASE, THE CRANKSHAFT, AND PISTONS.

USING A ROD-CONNECTING MACHINE,

A WORKER ASSEMBLES PISTON RODS TO HEADS FOR A PERFECT MATCH.

A LEAK-PROOF RING SURROUNDS EACH PISTON HEAD.

THE WORKER GENTLY SLIDES THE COMBINED UNIT

INTO THE CYLINDER BLOCK OF THE CRANKCASE.

ONCE ALL THE PISTONS ARE SET,

THE CYLINDER BLOCK MOVES TO A NEW WORKSTATION.

WITH THE AID OF A LIFTING DEVICE,

A WORKER LOWERS THE CRANKSHAFT ONTO A WORKTABLE.

USING LUBRICATED CLAMPS, HE INSTALLS AND FASTENS

THE CONNECTING RODS OF EACH PISTON TO THE CRANKSHAFT

USING AN AIR-IMPACT SCREWDRIVER.

AFTER SECURING THE PISTON RODS,

THE WORKER ADDS METAL TIMING CHAINS TO THE CRANKSHAFT.

TOO HEAVY TO HANDLE MANUALLY, USING A MECHANIZED LIFTER,

A WORKER LOWERS THE CRANKSHAFT

INTO THE CASING OF THE CRANKCASE,

FIRMLY ATTACHING IT INTO POSITION.

HE ALSO CHECKS THAT ALL MOVING PARTS ARE FUNCTIONAL.

AS THE TWO SEPARATE CASES OF THE CRANKCASE

ROLL INTO A CONTAINMENT ROOM,

TRANSFER ROBOTS RAISE ONE PART ONTO THE OTHER.

THE TWO PARTS ARE PRECISELY ALIGNED AND LINKED.

THE SIX PISTONS ARE NOW IN

HORIZONTALLY OPPOSITE POSITIONS OF ONE ANOTHER.

A WORKER SHIFTS THE NEW ENGINE BLOCK

INTO A CARRIER CALLED A CROSSMEMBER,

WHICH TRANSPORTS THE ENGINE TO SELECT STATIONS

FOR FURTHER ASSEMBLY.

IN THE NEXT CIRCUIT, A WORKER INSTALLS A CYLINDER HEAD GASKET

ONTO THE ENGINE BLOCK,

WHICH WILL EXIST BETWEEN THE TWO HOUSING PARTS.

THE ACCOMPANYING CYLINDER-HEAD SECTION,

WHICH HOUSES THE CAMSHAFT,

IS PRECISELY FASTENED INTO PLACE WITH AN AIR-IMPACT WRENCH.

THE WORKER ROTATES THE ENGINE BLOCK

AND INSTALLS A SECOND CYLINDER HEAD GASKET

ONTO THE OTHER END OF THE ENGINE BLOCK.

HE LOWERS ANOTHER LARGE PIECE OF THE ENGINE BLOCK

WITH THE HELP OF A LIFTING DEVICE.

THE WORKER ALSO PUTS LARGE BOLTS INTO SPECIFIC POSITIONS

BEFORE SENDING THE NEAR-COMPLETE ENGINE

TO ANOTHER SECTION INVOLVING MORE AUTOMATION.

ON THE CROSSMEMBER,

THE ENGINE BLOCK SHUTTLES TO A NEW WORKSTATION.

AFTER THE DOUBLE-OVERHEAD CAMSHAFT IS COMPLETE,

A ROBOT INSTALLS AND FASTENS A COVER.

EACH SCREW IS CAREFULLY PUT INTO PLACE

AND TURNED BY A MEASURED ROTATION.

THE TURNING POWER IS EXTREMELY PRECISE

FOR A WELL-SEALED COMPLETION,

AVOIDING ANY UNNECESSARY TIGHTNESS OR DAMAGE.

THE ENTIRE ENGINE ASSEMBLY ROTATES

AND IS SET TO A NEW POSITION

BEFORE ENTERING A CABINET FOR A COLD TEST.

THIS ASSESSMENT DEVICE CHECKS THE NEW ENGINE WITH A LEAK TEST,

FLOW TEST, AND PRESSURE TEST

BY SIMULATING ITS FUNCTION WITH THE ASSISTANCE

OF AN AUTOMATED AIR PUMP.

WHEN THE TESTS ARE SUCCESSFUL,

THE CENTRAL PART OF THE FLAT ENGINE IS COMPLETE.

THE INSTALLATION OF TUBING IS NEXT.

PLACEMENT OF THE INTAKE MANIFOLD,

FOLLOWED BY EXHAUST MANIFOLD,

COMPLETE THE 3.4-LITER V6 ENGINE ASSEMBLY.

AT THE END OF THE LINE,

A WORKER TRANSFERS THE MOTOR TO A ROBOTIC CART.

USING GUIDANCE SIGNALS, THE CART TRAVELS

TO THE PORSCHE 911 VEHICLE ASSEMBLY LINE.

Narrator: THE INTERIOR OF THE PORSCHE 911 IS IMPRESSIVELY SOPHISTICATED,

SUITED WITH THE FINEST LEATHER IN A VARIETY OF COLORS.

THE CAR'S INTERIOR IS DESIGNED TO SUIT ANY CUSTOMER'S TASTE.

IN THE UPHOLSTERY SHOP,

LEATHER COLOR IS CHOSEN ACCORDING TO CUSTOMER CHOICE.

MANUFACTURER-APPROVED COWHIDE,

BOUGHT FROM CERTIFIED CATTLE HERDS,

SITS ON AN OPTICAL SCANNING TABLE

WHICH REMOVES ANY WRINKLES.

WITHIN SECONDS, RECOGNITION BY A HIGH-DEFINITION CAMERA

ASSESSES THE LEATHER'S SIZE, HOLES, AND MARKS IN DETAIL.

USING A SPECIAL MOUSE, THE WORKER MARKS DEFECTS

AND TRACES THOSE AREAS FOR FURTHER RECOGNITION.

THIS ELIMINATES ANY IMPERFECTIONS

AND IS ESSENTIAL TO CUTTING THE LEATHER INTO PIECES.

THE CAR INTERIOR REQUIRES THE LEATHER OF FIVE COWS,

AND IN THIS PROCESS, 40% OF THE LEATHER IS DISCARDED.

ONCE COMPLETE, THE WORKER PLACES A CODE ON THE SKIN

FOR IDENTIFICATION IN THE NEXT PROCESS.

A WORKER SPREADS THE LEATHER ON AN AUTOMATED CUTTING TABLE.

WITH THE IDENTIFICATION CODE,

THE LEATHER WILL BE CUT INTO PATTERNED PIECES.

THE COMPUTERIZED SYSTEM CONFIRMS THE CUTTING OF ALL PIECES

WITH PRECISE CUSTOMIZATION.

ON THE CUTTING TABLE, A VERY SMALL ecoJET

SPRAYS WATER AT A HIGH PRESSURE,

REPEATEDLY CREATING CONTOURS AND OUTLINES

WITHOUT TEARING OR DAMAGING THE LEATHER.

THE WORKER REMOVES ANY RESIDUE OR REMAINS,

KEEPING THE PATTERNED PIECES

SLICED BY THE ecoJET LEATHER CUTTER.

WEARING WHITE GLOVES AND USING A SPATULA

TO AVOID ANY WEAR ON THE MATERIAL,

HE STACKS EACH NEW PIECE WITH OTHERS

TO SEND TO THE SEWING ROOM.

USING INDUSTRIAL SEWING MACHINES,

SKILLED GARMENT WORKERS STITCH THE PIECES OF LEATHER TOGETHER

WITH HIGH-STRENGTH NEEDLES AND THREAD.

THE THREAD COLORS OFTEN MATCH OR CONTRAST

THE PIGMENT OF THE LEATHER CUTOUTS.

A WORKER PLACES THE UPPER UNIT OF THE DASHBOARD

AND ITS LEATHER COUNTERPARTS,

INFUSED WITH HIGH-STRENGTH BONDING GLUE,

ONTO A CASTING UNIT.

LOWERING A PRESSING DEVICE,

IT ESTABLISHES A MARRIAGE OF THE MATERIALS.

ENSURING THAT EACH SECTION OF THE LEATHER IS PROPERLY FITTED,

THE WORKER PULLS THE MATERIAL TO SMOOTH IT ON ALL SIDES,

MATCHING THE SEAMS TO THE FRAME.

PRECISION FINISHING TOOLS, LIKE A DIRECTIONAL HEATER,

CERTIFY THAT THE LEATHER IS PERFECTLY JOINED

INTO EVERY CAVITY OF THE DASHBOARD FRAME

WITHOUT OVERLOOKING ANY IMPERFECTIONS.

THE WORKER PLACES THE DASHBOARD PART

INTO A SPECIAL KILN TO FULLY DRY THE ADHESIVE

AND PERFECTLY JOIN THE MATERIALS.

WHEN DRIED, THE UNIT TRAVELS TO A NEW WORKSTATION.

A WORKER PLACES A REAR PLASTIC PANEL

ONTO THE INSIDE OF THE LEATHER-BOUND DASHBOARD.

AN AUTOMATED COVER CONTAINS THE AREA

WHILE A BONDING DEVICE BRACES THE PARTS WITH FASTENING TIES.

THE SHAPE AND CONSTRUCTION OF THE UPPER DASHBOARD

MAKE INSTALLING THE CAR'S DIALS AND SWITCHES EASY.

ONCE THE FULLY UPHOLSTERED DASHBOARD IS PARTIALLY EQUIPPED,

WORKERS SECURELY INSTALL IT INTO THE COCKPIT

USING A MECHANICAL LIFTER AND AIR-IMPACT SCREWDRIVERS.

THE CAR'S BODY MOVES ALONG THE VEHICLE ASSEMBLY LINE,

PROTECTED BY VINYL COVERINGS.

AND WITHOUT THE DOORS,

INTERIOR INSTALLATION WORK IS MUCH EASIER TO EXECUTE,

LIKE PLACING A GLASS SUNROOF.

TWO WINDOW-ASSEMBLY ROBOTS ARE RESPONSIBLE

FOR THE INSTALLATION OF THE FRONT AND REAR WINDSHIELDS.

THE FIRST ROBOT APPLIES AN ADHESIVE PASTE

AROUND THE GLASS EDGES

AS THE SECOND ROBOT GENTLY ALIGNS THE WINDOW INTO POSITION

USING INFRARED SENSORS FOR ACCURACY.

AS A NEXT-LEVEL SPORTS CAR, THE CONSTRUCTION

OF THE PORSCHE 911 CONTINUES ON MULTIPLE STORIES --

ALL WITHIN THE SAME BUILDING.

Narrator: THE PORSCHE 911 ENGINE, TRANSMISSION, AND AXLES

ARE MOUNTED BY A SYNCHRONOUS ELEVATING PLATFORM,

WHERE THE PARTS ARE INSERTED INTO THE BODY.

WORKERS CAN ALSO INSTALL CUSTOMIZED VARIANTS

LIKE ALL-WHEEL DRIVE, CERAMIC BRAKES,

OR A SPORTS CHASSIS.

ADDING TO THE CAR'S ASSEMBLY, A WORKER AFFIXES THE GEARBOX

TO THE 3.4-LITER V6 ENGINE BLOCK.

BOTH PARTS ARE LOWERED WITH A HOIST ONTO A WORKSTATION

WHERE SYSTEMS, INCLUDING THE DRIVETRAIN AND SUSPENSION,

WILL JOIN THE MACHINERY.

WORKERS ATTACH AND ALIGN THE EXHAUST SYSTEM.

RAISED AND TRANSPORTED BY A SUSPENDED CONVEYOR LIFT,

WORKERS SLOWLY LOWER THE BODY

TO ENSURE THE ENGINE BLOCK, DAMPERS, AND SUSPENSION

SLIDE DIRECTLY INTO THEIR DESIGNATED LOCATIONS

WITHOUT ANY COMPLICATIONS.

COMMONLY KNOWN AS THE MARRIAGE OF ELEMENTS,

WORKERS BOLT THE DRIVETRAIN AND CHASSIS

TO THE BODY OF THE CAR.

ADDING TO THE CAR'S FLAIR AND SAFETY,

TWO WORKERS MOUNT THE BUMPERS.

ANOTHER WORKER, USING A PRESET MOLD,

ATTACHES THE LEGENDARY NAMEPLATE WITH CARE AND PRECISION.

A SIMPLE ADHESIVE AND FINISHING ROLLER

KEEP IT TOGETHER.

AND A QUICK WIPE-DOWN ADDS TO THE SHINE OF THE CAR'S IDENTITY.

THE CAR NOW ENTERS THE FINAL STATIONS

OF THE VEHICLE ASSEMBLY LINE.

USING A LIFTING DEVICE,

A WORKER MOUNTS THE TIRES AND RIMS ONTO EACH WHEEL PLATE.

THE COMPANY'S ASSEMBLY PLANNING

USES THE COST-EFFECTIVE "JUST IN TIME" STRATEGY,

WHICH AVOIDS KEEPING ANY INVENTORY OF PARTS IN OVERSTOCK.

AT THIS STATION, THE CAR REGAINS ITS DOORS.

MANUFACTURED OFFSITE BY RECARO, A NAME SYNONYMOUS WITH RACING,

THE SPORTY, LEATHER BUCKET SEATS ARE FIT INTO THE CABIN.

AFTER BODY AND ELECTRICAL ADJUSTMENTS

ON THE VEHICLE'S ASSEMBLY LINE,

THE CAR WILL UNDERGO DRIVING TESTS.

A WORKER DRIVES THE CAR ONTO TEST ROLLERS.

COMPUTERIZED LASER SENSORS SCAN LABELS ON EACH WHEEL

AND MONITOR THEIR MOVEMENT

FOR ALIGNMENT, TIRE BALANCE, AND HANDLING QUALITIES.

AT ANOTHER WORKSTATION, A WORKER SHAKES THE WHEELS LATERALLY

TO MANUALLY CHECK THE AXLE ALIGNMENT.

SENSORS AND COMPUTER SOFTWARE HELP PERFECT THE ADJUSTMENTS.

NEXT, A WORKER ASSESSES THE ORIENTATION

OF THE CAR'S OPTICAL BLOCKS AND LIGHT UNITS.

A WORKER DRIVES THE CAR ONTO ANOTHER SET OF TEST ROLLERS.

IN THIS EXERCISE, WHILE THE ACCELERATOR IS PRESSED,

A DEVICE CALLED A DYNAMOMETER RECORDS MOTOR PERFORMANCE.

IT MEASURES THE POWER AND TORQUE OUTPUT

DELIVERED BY THE 3.4-LITER FLAT 6-CYLINDER ENGINE.

A WATER-LEAKAGE TEST USES MID-PRESSURE SHOWERS

AS A WORKER SEARCHES FOR LEAKS IN THE CABIN USING A FLASHLIGHT.

WHEN THE EXTENSIVE DRIVE TESTS ARE SUCCESSFUL,

THE CAR IS READY TO EXIT THE PLANT.

THE FACTORY IN THE ZUFFENHAUSEN DISTRICT OF STUTTGART, GERMANY,

PRODUCES MORE THAN 40,000 CARS PER YEAR --

TWICE THE AMOUNT SINCE THE EARLY '90s.

ONLY VARIANTS OF THIS MODEL AND ANOTHER MODEL

ARE ASSEMBLED HERE.

INSTANTLY RECOGNIZABLE

AND ORIGINALLY ENGINEERED FOR THE RACETRACK,

THIS CAR CONTINUES TO STIR EMOTION AND GARNER ATTENTION,

JUST AS IT DID IN ITS ORIGINAL YEAR.

WITH A PERFECT LEATHER INTERIOR, ADVANCED TECHNOLOGY,

AND A POWERFUL 3.4-LITER V6 ENGINE,

THIS CAR IS ONE OF THE MOST CAPTIVATING SPORTS CARS

IN THE ENTIRE WORLD.

ALTHOUGH A GRAND DEPARTURE FROM THE FIRST 911,

THIS CAR STILL RETAINS A LOT OF THE ORIGINAL STYLING

WITH A MODERN EDGE

AND THE GIFT OF NEW AERODYNAMICS.

THIS CAR IS NO EXCEPTION TO THE RULE...

...WHICH HAS MADE IT CLASSICALLY APPEALING

FOR MORE THAN 40 YEARS.

DREAM CARS -- THE COMPACT PORSCHE 911

IS POWERFULLY AGILE AND VISUALLY LEGENDARY

WITHOUT COMPROMISE.