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Narrator: TODAY ON
"HOW IT'S MADE: DREAM CARS,"
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00:00:04,163 --> 00:00:06,830
THE BMW M6, A STUDY IN
STREAMLINED ELEGANCE
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00:00:06,832 --> 00:00:08,724
AND LUXURIOUS POWER.
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00:00:17,285 --> 00:00:20,353
-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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00:00:23,316 --> 00:00:24,908
Narrator:
FOR MORE THAN 40 YEARS,
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BMW's M DIVISION HAS BEEN
CREATING THE CELEBRATED
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00:00:27,980 --> 00:00:30,239
M MODEL, HIGH-PERFORMANCE CARS
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00:00:30,241 --> 00:00:32,900
WITH POWER TRAINS EVOLVED
FROM THE WORLD OF RACING
10
00:00:32,902 --> 00:00:34,869
TO MEET THE NEEDS OF THE STREET.
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00:00:37,131 --> 00:00:40,933
THE M6 HAS ITS ROOTS
IN THIS CAR.
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00:00:40,935 --> 00:00:44,262
IN 1983, THE M DIVISION
TOOK A GRAND TOUR
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00:00:44,264 --> 00:00:46,455
FROM THE CAR MAKER'S
LUXURY 6 SERIES
14
00:00:46,457 --> 00:00:48,725
AND M-IFIED IT INTO A SPORTS CAR
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00:00:48,727 --> 00:00:51,719
IN THE GUISE
OF A PLUSH SEDAN,
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00:00:51,721 --> 00:00:57,351
THE BMW M635 CSi.
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00:00:57,353 --> 00:01:02,273
ALL M CARS CAN BE TRACED BACK
TO THE LEGENDARY M1.
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00:01:02,275 --> 00:01:04,341
ORIGINALLY DEVELOPED
FOR THE RACETRACK,
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00:01:04,343 --> 00:01:07,603
THE M DIVISION TURNED IT
INTO A SERIES PRODUCTION CAR.
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00:01:09,766 --> 00:01:12,767
THE M6 REMAINS TRUE
TO ITS LINEAGE.
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00:01:12,769 --> 00:01:15,561
FROM THE OUTSIDE,
IT HAS THE GRACEFUL LINES
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00:01:15,563 --> 00:01:20,224
AND POLISH OF A LUXURIOUS
HIGH-END SEDAN.
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00:01:20,226 --> 00:01:22,619
BUT UNDER THE HOOD LURKS
A BRAWNY POWER TRAIN
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00:01:22,621 --> 00:01:25,355
TUNED TO ACHIEVE
IMPRESSIVE FUEL ECONOMY,
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00:01:25,357 --> 00:01:26,581
WHILE, SIMULTANEOUSLY,
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00:01:26,583 --> 00:01:28,183
THE CHASSIS DELIVERS PRECISION
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00:01:28,185 --> 00:01:30,878
HANDLING AT HIGH SPEEDS
IN ANY WEATHER.
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00:01:36,243 --> 00:01:37,843
IN THE EARLY 1990s,
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00:01:37,845 --> 00:01:40,571
BMW INVENTED A NEW KIND
OF COMPOUND BRAKE
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00:01:40,573 --> 00:01:42,306
DISC TO HANDLE THE MASSIVE
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00:01:42,308 --> 00:01:46,595
ACCELERATING POWER
OF ITS M CARS.
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00:01:46,597 --> 00:01:48,129
UNLIKE CONVENTIONAL DISCS,
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00:01:48,131 --> 00:01:50,465
BMW MAKES THESE COMPOUND BRAKES
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00:01:50,467 --> 00:01:53,193
FROM MULTIPLE MATERIALS.
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00:01:53,195 --> 00:01:56,722
TO REDUCE THE UNSPRUNG
WEIGHT OF THE WHEELBASE,
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00:01:56,724 --> 00:02:00,484
THE OUTER COVER OF THE DISC
IS MADE OF ALUMINUM.
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00:02:00,486 --> 00:02:02,285
THIS CONNECTS TO THE PERFORATED
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00:02:02,287 --> 00:02:04,413
INNER-VENTED CAST
IRON FRICTION RING
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00:02:04,415 --> 00:02:08,209
VIA STAINLESS STEEL PINS
WHICH ALLOW THE TWO METALS
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00:02:08,211 --> 00:02:09,744
TO EXPAND AND CONTRACT
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00:02:09,746 --> 00:02:11,671
WITHOUT DEFORMING EACH OTHER.
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00:02:15,835 --> 00:02:18,236
A TECHNICIAN ATTACHES
THE REAR BRAKE CALIPER,
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WHICH INCLUDES
THE PARKING BRAKE.
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00:02:21,433 --> 00:02:23,826
THE SPECIALIZED
M CAR COMPOUND BRAKES
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00:02:23,828 --> 00:02:25,494
ARE COLOR-CODED BLUE.
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00:02:28,357 --> 00:02:31,358
A TEAM MEMBER LOADS THE PARTS
FOR A FRONT AXLE CARRIER
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00:02:31,360 --> 00:02:33,885
INTO A COMPLEX JIG
IN PREPARATION
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00:02:33,887 --> 00:02:36,580
FOR THE WELDING PROCESS.
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00:02:36,582 --> 00:02:39,050
WHILE THE M6 BEARS
THE COSMETIC RESEMBLANCE
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00:02:39,052 --> 00:02:42,712
TO OTHER BMW 6 SERIES CARS,
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00:02:42,714 --> 00:02:46,975
THE GEOMETRY OF ITS STRUCTURE
IS VERY DISSIMILAR.
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00:02:46,977 --> 00:02:50,637
NOT ONLY IS IT MORE
TORSIONALLY RIGID,
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00:02:50,639 --> 00:02:52,397
THE KINEMATICS OF THE M6
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00:02:52,399 --> 00:02:53,799
ARE CONFIGURED VERY DIFFERENTLY
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00:02:53,801 --> 00:02:56,460
FROM AN ORDINARY 6.
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00:02:56,462 --> 00:02:58,195
THE FRONT AXLE CARRIER,
FOR INSTANCE,
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00:02:58,197 --> 00:03:00,523
HAS BEEN ENGINEERED
TO HELP THE CAR HANDLE
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00:03:00,525 --> 00:03:04,585
PRECISELY AT MUCH
HIGHER SPEEDS.
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00:03:04,587 --> 00:03:06,921
ONCE ALL THE PARTS
ARE LOADED INTO THE JIG,
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00:03:06,923 --> 00:03:09,249
IT CLAMPS THEM FIRMLY IN PLACE.
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00:03:14,615 --> 00:03:18,274
THREE ROBOTS UNDERTAKE
THE ALUMINUM WELDING OPERATION.
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00:03:18,276 --> 00:03:19,743
ONE ROBOT HOLDS THE JIG
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IN A PRECISELY
SPECIFIED POSITION
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SO THE OTHER TWO KNOW
EXACTLY WHERE THE PARTS
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THEY'RE WELDING ARE SITUATED.
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00:03:28,237 --> 00:03:29,695
THEY USE THE METAL INERT GAS,
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00:03:29,697 --> 00:03:31,630
OR MIG, WELDING PROCESS
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00:03:31,632 --> 00:03:33,291
AND COMPLETE
THE FRONT AXLE CARRIER
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00:03:33,293 --> 00:03:38,688
IN JUST 90 SECONDS.
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00:03:38,690 --> 00:03:40,623
NOW, THE PROTECTIVE
SHIELD LIFTS,
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00:03:40,625 --> 00:03:44,452
AND THE TECHNICIAN CAN ENTER,
SCAN THE NECESSARY INFORMATION,
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00:03:44,454 --> 00:03:49,441
VISUALLY INSPECT THE WORK
AND REMOVE THE CARRIER.
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00:03:49,443 --> 00:03:51,376
THIS LIGHTWEIGHT COMPONENT
HAS A TOTAL
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00:03:51,378 --> 00:03:53,703
OF 22 DIFFERENT PARTS
AND EIGHT NUTS.
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00:03:53,705 --> 00:03:58,267
FROM START TO FINISH, IT'S TAKEN
16 1/2 MINUTES TO BUILD.
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00:04:01,931 --> 00:04:03,997
TEAM MEMBERS MOUNT
THE FRONT BRAKE
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00:04:03,999 --> 00:04:06,126
DISCS ONTO THE AXLE CARRIER.
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00:04:10,390 --> 00:04:12,457
BETWEEN THE TWO LAYERS
OF THE BRAKE DISCS
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00:04:12,459 --> 00:04:15,152
ARE TURBINE-SHAPED GAPS
FOR VENTILATION.
80
00:04:17,289 --> 00:04:21,817
THE TURBINES VENTILATE THE AIR
EITHER TO THE RIGHT OR THE LEFT.
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00:04:21,819 --> 00:04:23,810
SO EACH BRAKE DISC IS HANDED
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00:04:23,812 --> 00:04:26,305
AND MUST BE MATCHED
TO THE CORRECT SIDE.
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00:04:32,038 --> 00:04:34,597
A TECHNICIAN TRANSFERS
THE FRONT AXLE CARRIER
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00:04:34,599 --> 00:04:37,433
AND HUB ASSEMBLIES
TO A DIFFERENT JIG,
85
00:04:37,435 --> 00:04:40,328
WHERE IT WILL BE JOINED
BY THE REST OF THE POWER TRAIN.
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00:04:44,292 --> 00:04:47,486
BMW PIONEERED THE USE
OF ALUMINUM SUSPENSION SYSTEMS
87
00:04:47,488 --> 00:04:51,181
BACK IN THE 1990s.
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00:04:51,183 --> 00:04:53,250
ASIDE FROM A FEW
STEEL BEARINGS,
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00:04:53,252 --> 00:04:56,078
THIS CARRIER IS ALMOST
ENTIRELY ALUMINUM.
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00:05:10,053 --> 00:05:14,547
Narrator: THE BMW M6 FEATURES
A CARBON FIBER ROOF PANEL.
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00:05:14,549 --> 00:05:16,708
CARBON FIBER IS
STRONG AND RIGID.
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00:05:16,710 --> 00:05:18,577
AND BECAUSE
IT'S SUPER LIGHTWEIGHT,
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00:05:18,579 --> 00:05:20,904
USING IT IN THE ROOF
IMPROVES THE CAR'S HANDLING
94
00:05:20,906 --> 00:05:23,040
BY LOWERING
THE CENTER OF GRAVITY.
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00:05:25,969 --> 00:05:29,163
A TECHNICIAN ENCLOSES
A PROTOTYPE M6 IN A BOOTH
96
00:05:29,165 --> 00:05:32,925
DESIGNED TO ASSESS
THE CAR'S GEOMETRY.
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00:05:32,927 --> 00:05:36,320
THIS ASSESSMENT
IS COMPLETELY AUTOMATED.
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00:05:36,322 --> 00:05:38,522
A 3-D MEASUREMENT
ROBOT IS EQUIPPED
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00:05:38,524 --> 00:05:40,383
WITH TWO CAMERAS
THAT WORK TOGETHER
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00:05:40,385 --> 00:05:42,185
TO CREATE
THREE-DIMENSIONAL IMAGES
101
00:05:42,187 --> 00:05:43,945
OF THE CAR'S SURFACES.
102
00:05:46,450 --> 00:05:48,942
IF, FOR INSTANCE,
A TEST DRIVER NOTES WIND NOISE
103
00:05:48,944 --> 00:05:50,944
WHILE DOING LAPS
ON THE TEST TRACK,
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00:05:50,946 --> 00:05:53,672
THIS ROBOT CAN BE USED
TO DISCOVER THE SOURCE
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00:05:53,674 --> 00:05:56,867
OF THE NOISE.
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00:05:56,869 --> 00:06:00,463
THIS WAY, BMW CAN IRON
OUT ANY POTENTIAL PROBLEMS
107
00:06:00,465 --> 00:06:04,959
BEFORE STARTING UP
FULL-SCALE PRODUCTION.
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00:06:04,961 --> 00:06:07,562
THE SYSTEM CAN ALSO QUICKLY
ENSURE MANUFACTURING
109
00:06:07,564 --> 00:06:09,556
QUALITY BY
COMPARING THE SURFACES
110
00:06:09,558 --> 00:06:14,553
CAPTURED IN THE IMAGES
TO THE DESIGN PARAMETERS.
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00:06:14,555 --> 00:06:17,681
WHEN ASSEMBLING A CAR
FROM 20,000 DIFFERENT PARTS,
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00:06:17,683 --> 00:06:19,349
IT'S VITALLY IMPORTANT
TO BE CERTAIN
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00:06:19,351 --> 00:06:21,710
THAT THOSE PARTS
ARE BEING MANUFACTURED
114
00:06:21,712 --> 00:06:23,979
WITH AS MUCH PRECISION
AS POSSIBLE.
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00:06:30,104 --> 00:06:33,831
IN THE BODY SHOP, BMW USES
A CAREFUL MIX OF MATERIALS
116
00:06:33,833 --> 00:06:35,500
TO CREATE THE M6.
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00:06:38,062 --> 00:06:42,390
THE DOORS, FOR INSTANCE,
ARE MADE OF PRESSED ALUMINUM.
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00:06:42,392 --> 00:06:45,452
RESEARCH AND DEVELOPMENT
CARRIED OUT BY BMW'S ALUMINUM
119
00:06:45,454 --> 00:06:47,721
COMPETENCE CENTER
HAS LED TO NEW METHODS
120
00:06:47,723 --> 00:06:50,649
OF PROCESSING THE METAL,
121
00:06:50,651 --> 00:06:52,651
ALLOWING THE CARMAKER
TO INCORPORATE
122
00:06:52,653 --> 00:06:55,279
MORE COMPLEX
DESIGN ELEMENTS,
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00:06:55,281 --> 00:06:57,940
LIKE THE LINE WHICH RUNS
THE LENGTH OF THE CAR
124
00:06:57,942 --> 00:07:02,937
FROM THE FRONT FENDERS
TO THE REAR FLANKS.
125
00:07:02,939 --> 00:07:05,798
THIS LINE, OFTEN REFERRED
TO AS THE CHARACTER LINE,
126
00:07:05,800 --> 00:07:08,067
IS A STANDARD FEATURE
OF CAR DESIGN.
127
00:07:08,069 --> 00:07:10,262
BUT PRESSING IT
INTO ALUMINUM PANELING
128
00:07:10,264 --> 00:07:11,930
IS SURPRISINGLY TRICKY.
129
00:07:15,360 --> 00:07:18,153
ONCE THE TECHNICIAN
HAS INSTALLED THE DOOR,
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00:07:18,155 --> 00:07:20,355
HE USES A SET
OF PRECISION CALIPERS
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00:07:20,357 --> 00:07:22,149
TO ENSURE THE GAPS
BETWEEN THE DOOR
132
00:07:22,151 --> 00:07:25,653
AND OTHER PANELS MEET
THE SPECIFIED TOLERANCES.
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00:07:31,978 --> 00:07:35,038
THE FRONT FENDERS ARE MADE
OF A THERMOFORMED PLASTIC.
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00:07:35,040 --> 00:07:38,967
SINCE MINOR ACCIDENTS TEND
TO DAMAGE THESE PANELS,
135
00:07:38,969 --> 00:07:42,437
REPLACEMENT COST IS
A DESIGN CONSIDERATION.
136
00:07:42,439 --> 00:07:44,364
THIS MATERIAL
IS BOTH LIGHTWEIGHT
137
00:07:44,366 --> 00:07:47,459
AND RELATIVELY INEXPENSIVE.
138
00:07:47,461 --> 00:07:50,462
TO ENSURE THE FENDERS
ARE PERFECTLY POSITIONED,
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00:07:50,464 --> 00:07:52,657
THE TEAM MEMBERS LOWER
A COMPLEX ALIGNMENT
140
00:07:52,659 --> 00:07:54,917
JIG AND CLAMP
IT IN PLACE.
141
00:07:57,255 --> 00:08:00,181
THEY THEN DO THE FINAL
ATTACHMENTS USING DRIVERS
142
00:08:00,183 --> 00:08:03,476
THAT ARE PROGRAMMED TO ENSURE
THEY ACHIEVE THE CORRECT TORQUE,
143
00:08:03,478 --> 00:08:08,940
ANGLE AND NUMBER OF TURNS
WITH EACH FASTENER THEY INSTALL.
144
00:08:08,942 --> 00:08:12,869
THE GAPS MUST BE WITHIN
THE SPECIFIED PARAMETERS.
145
00:08:12,871 --> 00:08:14,871
THIS ISN'T JUST
ABOUT LOOKS --
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00:08:14,873 --> 00:08:17,266
WITHOUT THE CORRECT GAP
DISTANCE BETWEEN THE DOOR PANEL
147
00:08:17,268 --> 00:08:18,800
AND THE FENDER,
FOR INSTANCE,
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00:08:18,802 --> 00:08:21,162
THE DOOR WOULDN'T BE
ABLE TO OPEN PROPERLY.
149
00:08:24,025 --> 00:08:27,260
THE CAR IS READY TO MOVE
TO THE NEXT BODY SHOP STATION.
150
00:08:29,822 --> 00:08:33,016
LIKE THE DOORS, THE HOOD
IS MADE OF PRESSED ALUMINUM.
151
00:08:35,486 --> 00:08:37,846
THE OUTER LAYER FEATURES
THE CURVES AND LINES
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00:08:37,848 --> 00:08:41,908
THAT ARE EMBLEMATIC
OF A BMW 6 CAR,
153
00:08:41,910 --> 00:08:44,903
WHILE THE INTERIOR LAYER
PROVIDES STRUCTURAL SUPPORT
154
00:08:44,905 --> 00:08:46,304
AND THE ATTACHMENT POINTS
155
00:08:46,306 --> 00:08:49,500
WHERE THE TEAM MEMBER CAN FASTEN
THE COMPONENT TO THE CHASSIS.
156
00:08:55,667 --> 00:08:59,460
THE INSTALLATION
JIG INCLUDES A GAP GAUGE.
157
00:08:59,462 --> 00:09:01,388
THE TECHNICIAN USES
A HANDHELD GAUGE
158
00:09:01,390 --> 00:09:04,983
TO DO THE REST.
159
00:09:04,985 --> 00:09:07,118
UNLIKE
THE THERMOPLASTIC FENDERS,
160
00:09:07,120 --> 00:09:09,279
THE MATERIAL THAT MAKES UP
THE TRUNK LID
161
00:09:09,281 --> 00:09:12,149
IS SHEET-MOLDED,
FIBER-REINFORCED COMPOSITE.
162
00:09:15,212 --> 00:09:19,073
IT'S NOW TIME
FOR SURFACE FINISHING.
163
00:09:19,075 --> 00:09:20,607
A HIGHLY TRAINED TECHNICIAN RUNS
164
00:09:20,609 --> 00:09:22,067
HIS HAND OVER THE PANELING
165
00:09:22,069 --> 00:09:24,604
WITH A GLOVE
MADE OF A SPECIAL COTTON
166
00:09:24,606 --> 00:09:26,096
THAT HELPS HIM FEEL DISTORTIONS
167
00:09:26,098 --> 00:09:30,894
SO SMALL THEY'RE INVISIBLE
TO THE NAKED EYE.
168
00:09:30,896 --> 00:09:34,355
HE REMOVES THE FLAWS
WITH A FINE-GRAIN PAD
169
00:09:34,357 --> 00:09:37,551
AND THEN FINISHES THE JOB
WITH AN ORBITAL POLISHER.
170
00:09:39,955 --> 00:09:41,155
THE SPECIALIST EXAMINES
171
00:09:41,157 --> 00:09:43,615
AND FINISHES
EVERY SURFACE OF THE CAR
172
00:09:43,617 --> 00:09:47,845
BEFORE LETTING IT MOVE ON
TO THE NEXT PHASE OF PRODUCTION.
173
00:09:47,847 --> 00:09:50,906
IN FACT, BMW USES
THIS SAME METHOD
174
00:09:50,908 --> 00:09:54,102
TO PERFECT THE SURFACES
OF EVERY CAR IT MAKES.
175
00:10:00,168 --> 00:10:02,727
BMW FIRST INTRODUCED
A CARBON ROOF
176
00:10:02,729 --> 00:10:07,658
ON THEIR M3 CSL IN 2003.
177
00:10:07,660 --> 00:10:09,726
THE DESIGN ELEMENT
HAS BEEN SO SUCCESSFUL
178
00:10:09,728 --> 00:10:11,920
AT LOWERING
A CAR'S CENTER OF GRAVITY
179
00:10:11,922 --> 00:10:14,514
WHILE REDUCING OVERALL WEIGHT
180
00:10:14,516 --> 00:10:16,116
THAT IT'S BECOME
A STANDARD FEATURE
181
00:10:16,118 --> 00:10:19,211
ON MOST BMW M CARS.
182
00:10:19,213 --> 00:10:20,947
WHILE SOME BOUTIQUE
CARMAKERS USE
183
00:10:20,949 --> 00:10:23,541
A HIGHLY ARTISANAL
HAND-LAYING PROCEDURE
184
00:10:23,543 --> 00:10:26,435
TO CREATE CARBON
FIBER COMPONENTS,
185
00:10:26,437 --> 00:10:28,804
BMW HAS INDUSTRIALIZED
THE PROCESS
186
00:10:28,806 --> 00:10:31,199
AT THEIR LANDSHUT FACTORY
NEAR MUNICH.
187
00:10:38,946 --> 00:10:40,704
Narrator:
THE M6 HAS A HIGH-REV,
188
00:10:40,706 --> 00:10:42,907
TWIN-TURBOCHARGED 4.4-LITER
189
00:10:42,909 --> 00:10:46,169
V-8 THAT DEVELOPS 560 HORSEPOWER
190
00:10:46,171 --> 00:10:48,362
WITH HIGH-PRECISION
DIRECT INJECTION,
191
00:10:48,364 --> 00:10:49,831
VARIABLE VALVE TIMING
192
00:10:49,833 --> 00:10:52,859
AND CONTINUOUSLY
VARIABLE CAMSHAFT CONTROL.
193
00:10:55,363 --> 00:10:57,289
BMW MACHINES THE LARGE PLATE
194
00:10:57,291 --> 00:10:59,424
GEAR OF THE DIFFERENTIAL
IN HOUSE
195
00:10:59,426 --> 00:11:04,780
BECAUSE IT'S A CRUCIAL ELEMENT
OF THE M6'S DRIVETRAIN.
196
00:11:04,782 --> 00:11:06,515
A POWERFUL MILLING MACHINE USES
197
00:11:06,517 --> 00:11:07,983
A SPECIALIZED TOOL
198
00:11:07,985 --> 00:11:10,511
TO MILL THE BLANK STEEL PLATE
INTO A COMPONENT
199
00:11:10,513 --> 00:11:13,272
THAT WILL PERFECTLY MATCH
WITH THE CONE GEAR.
200
00:11:16,737 --> 00:11:20,538
THIS HIGH-PRECISION ALIGNMENT
REDUCES FRICTION TO A MINIMUM,
201
00:11:20,540 --> 00:11:22,999
WHICH MEANS THAT THE GEARS
CAN TRANSMIT THE ENORMOUS
202
00:11:23,001 --> 00:11:24,334
TORQUE OF THE M ENGINE
203
00:11:24,336 --> 00:11:26,962
TO THE WHEELS
WITH MAXIMUM EFFICIENCY.
204
00:11:29,524 --> 00:11:31,525
THIS TRANSLATES
INTO THE ABILITY
205
00:11:31,527 --> 00:11:32,926
TO ACCELERATE THE CAR
206
00:11:32,928 --> 00:11:36,122
TO TOP SPEED WITH
SUPERIOR FUEL ECONOMY.
207
00:11:39,685 --> 00:11:42,011
ONCE THE GEAR HAS BEEN
FULLY MACHINED,
208
00:11:42,013 --> 00:11:46,207
IT'S TIME TO HARDEN IT
TO ENSURE DURABILITY.
209
00:11:46,209 --> 00:11:48,409
IT'S CRUCIAL THAT
A COMPONENT LIKE THIS ONE,
210
00:11:48,411 --> 00:11:50,637
WHICH WILL BE UNDER
CONSTANT HIGH STRESS,
211
00:11:50,639 --> 00:11:54,833
MUST BE ABLE TO RESIST TO WEAR.
212
00:11:54,835 --> 00:11:56,234
HARDENING STEEL IS A PROCEDURE
213
00:11:56,236 --> 00:11:58,762
NEARLY AS OLD
AS METALLURGY ITSELF.
214
00:11:58,764 --> 00:12:01,765
BUT HERE, BMW HAS TURNED
THE PROCESS INTO
215
00:12:01,767 --> 00:12:04,693
A HIGH-TECH OPERATION.
216
00:12:04,695 --> 00:12:07,388
THE GEARS SPEND
EXACTLY 308 MINUTES
217
00:12:07,390 --> 00:12:12,852
INSIDE AN OVEN
AT 1,742 DEGREES FAHRENHEIT.
218
00:12:12,854 --> 00:12:15,980
INSIDE THE OVEN, THEY CIRCULATE
ON A CAROUSEL-LIKE MECHANISM
219
00:12:15,982 --> 00:12:18,775
TO ENSURE UNIFORM HEATING.
220
00:12:18,777 --> 00:12:21,878
WHEN THEY EMERGE,
THEY'RE LITERALLY RED-HOT.
221
00:12:24,741 --> 00:12:26,867
THE SYSTEM THEN USES
A STREAM OF OIL
222
00:12:26,869 --> 00:12:29,136
TO COOL THEM DOWN
AT A SPECIFIC RATE
223
00:12:29,138 --> 00:12:32,164
TO GUARANTEE THAT THE COMPONENTS
ARE ALL IDENTICAL.
224
00:12:36,596 --> 00:12:38,596
A LARGE COOLING SYSTEM
SITS IN THE MIDDLE
225
00:12:38,598 --> 00:12:42,558
OF THE REAR AXLE TO HELP
KEEP ITS TEMPERATURE STABLE.
226
00:12:42,560 --> 00:12:46,087
A TECHNICIAN FITS THE REAR
AXLE CARRIER DOWN ONTO IT
227
00:12:46,089 --> 00:12:47,681
AND ENSURES
IT'S PROPERLY ALIGNED
228
00:12:47,683 --> 00:12:49,816
BEFORE REMOVING
THE LIFT ASSIST.
229
00:12:54,682 --> 00:12:57,040
BMW MAKES THE REAR AXLE CARRIER
230
00:12:57,042 --> 00:12:59,502
FROM HYDROFORMED ALUMINUM.
231
00:12:59,504 --> 00:13:01,236
THEY START WITH A ROUND TUBE
232
00:13:01,238 --> 00:13:03,172
WHICH THEY FILL WITH FLUID
233
00:13:03,174 --> 00:13:08,293
BEFORE APPLYING 51,000
POUNDS OF PRESSURE.
234
00:13:08,295 --> 00:13:10,029
THIS BLOWS THE METAL UP
LIKE A BALLOON,
235
00:13:10,031 --> 00:13:12,056
GIVING IT A BANANA-LIKE SHAPE.
236
00:13:15,028 --> 00:13:16,786
A SOPHISTICATED MECHANISM GRIPS
237
00:13:16,788 --> 00:13:19,122
THE REAR AXLE
ASSEMBLY IN POSITION
238
00:13:19,124 --> 00:13:22,651
AND THEN SLOWLY LIFTS AND LOWERS
THE AXLE PARTS IN A PROCESS
239
00:13:22,653 --> 00:13:24,712
DESIGNED TO RELEASE ANY TENSIONS
240
00:13:24,714 --> 00:13:26,914
THAT MIGHT BE IN THE COMPONENTS.
241
00:13:30,511 --> 00:13:33,204
THE MECHANISM ALSO ROTATES
THE DIFFERENTIAL
242
00:13:33,206 --> 00:13:35,006
TO RELEASE FURTHER TENSIONS.
243
00:13:35,008 --> 00:13:36,899
IT THEN ALIGNS THE HUBS.
244
00:13:39,470 --> 00:13:40,862
HERE, THE FRONT AXLE COMES
245
00:13:40,864 --> 00:13:42,864
ONTO THE POWER TRAIN
ASSEMBLY LINE,
246
00:13:42,866 --> 00:13:45,926
WHERE IT MEETS
THE ENGINE.
247
00:13:45,928 --> 00:13:49,687
THE LINE IS NOT
EXCLUSIVE TO THE M6.
248
00:13:49,689 --> 00:13:52,157
IN FACT, TECHNICIANS
MUST BE READY TO HANDLE
249
00:13:52,159 --> 00:13:54,284
ANY ONE OF NINE
DIFFERENT MODELS,
250
00:13:54,286 --> 00:13:56,219
INCLUDING SIX DIFFERENT 6s,
251
00:13:56,221 --> 00:13:58,814
ONE 5 AND TWO 7s
AS THEY ARRIVE
252
00:13:58,816 --> 00:14:01,175
IN VARYING SEQUENCES
ON THIS LINE.
253
00:14:04,080 --> 00:14:06,506
THIS IS PART OF
BMW'S PRODUCTION STRATEGY
254
00:14:06,508 --> 00:14:08,574
CALLED JUST IN SEQUENCE.
255
00:14:13,965 --> 00:14:16,165
JUST IN SEQUENCE, OR JIS,
256
00:14:16,167 --> 00:14:18,760
IS A METHOD OF HANDLING
INVENTORY THAT REFINES
257
00:14:18,762 --> 00:14:21,255
THE WELL-KNOWN
JUST IN TIME STRATEGY.
258
00:14:23,325 --> 00:14:26,719
MANAGERS PLAN THE PRODUCTION
SEQUENCE A WEEK IN ADVANCE
259
00:14:26,721 --> 00:14:28,053
AND INFORM SUPPLIERS
260
00:14:28,055 --> 00:14:30,848
TO DELIVER THE NECESSARY PARTS
TO THE PRODUCTION LINE
261
00:14:30,850 --> 00:14:32,817
EXACTLY WHEN THEY'RE REQUIRED.
262
00:14:37,182 --> 00:14:38,672
THE PROP SHAFT THE TECHNICIAN
263
00:14:38,674 --> 00:14:40,208
IS INSTALLING HERE,
FOR INSTANCE,
264
00:14:40,210 --> 00:14:43,003
HAS ONLY JUST ARRIVED
AT THIS STATION IN TIME
265
00:14:43,005 --> 00:14:46,064
TO BE FITTED INTO THIS
PRECISE M6 MODEL.
266
00:14:50,596 --> 00:14:53,263
USING THE JUST IN SEQUENCE
METHOD ELIMINATES THE NEED
267
00:14:53,265 --> 00:14:55,024
FOR DESIGNATED BUFFER AREAS
268
00:14:55,026 --> 00:14:57,092
WHERE PARTS ARE HELD TEMPORARILY
269
00:14:57,094 --> 00:14:59,553
AND DELIVERED TO THE LINE
JUST IN TIME.
270
00:15:02,683 --> 00:15:05,418
HELPING TO MAINTAIN
THE SWIFT RATE OF PRODUCTION,
271
00:15:05,420 --> 00:15:07,344
A TECHNICIAN CATCHES UP
TO THE POWER TRAIN
272
00:15:07,346 --> 00:15:09,747
JIG AND APPLIES
THE PROP SHAFT FASTENERS
273
00:15:09,749 --> 00:15:12,542
BEFORE INSTALLING
THE REAR AXLE CARRIER.
274
00:15:27,508 --> 00:15:31,202
Narrator: THE BMW M6 COMES AS
EITHER A TWO-DOOR COUPE,
275
00:15:31,204 --> 00:15:34,097
THE FOUR-DOOR GRAN COUPE
OR CONVERTIBLE.
276
00:15:34,099 --> 00:15:35,698
AS WITH MANY CARS
IN THE HIGH-END
277
00:15:35,700 --> 00:15:36,992
LUXURY SPORTS CATEGORY,
278
00:15:36,994 --> 00:15:39,428
CUSTOMERS CAN CONFIGURE
ITS SPECIFICATIONS
279
00:15:39,430 --> 00:15:41,989
TO THEIR PRECISE
NEEDS AND WISHES.
280
00:15:44,093 --> 00:15:46,818
THE FACT THAT EACH M6
IS CUSTOM-MADE
281
00:15:46,820 --> 00:15:48,621
IS THE REASON
EACH WIRING HARNESS
282
00:15:48,623 --> 00:15:50,448
IS UNIQUE TO EACH CAR.
283
00:15:52,518 --> 00:15:53,910
LIKE THE OTHER COMPONENTS,
284
00:15:53,912 --> 00:15:56,044
THE HARNESS ARRIVES
IN THE SEQUENCE REQUIRED
285
00:15:56,046 --> 00:15:59,841
TO FIT IT TO ITS MATCHING CAR.
286
00:15:59,843 --> 00:16:02,969
THE HARNESSES FOR THE M6
HAVE MORE THAN 2 1/2 MILES
287
00:16:02,971 --> 00:16:05,171
OF WIRING PACKAGED
WITH PRECISION
288
00:16:05,173 --> 00:16:06,898
FOR EASE OF INSTALLATION.
289
00:16:10,930 --> 00:16:12,529
THIS FACILITY HAS
A STATE-OF-THE-ART
290
00:16:12,531 --> 00:16:14,122
SWIVELING CONVEYOR SYSTEM
291
00:16:14,124 --> 00:16:16,391
DESIGNED TO ENHANCE
ERGONOMIC COMFORT
292
00:16:16,393 --> 00:16:18,386
BY ELIMINATING THE NEED
FOR TECHNICIANS
293
00:16:18,388 --> 00:16:20,288
TO PERFORM OVERHEAD WORK.
294
00:16:23,117 --> 00:16:26,277
HERE, THE SYSTEM
SWIVELS 180 DEGREES
295
00:16:26,279 --> 00:16:30,874
TO ALLOW A TEAM MEMBER
TO INSTALL THE GAS TANK.
296
00:16:30,876 --> 00:16:32,475
A LIFT ASSIST IS NECESSARY
297
00:16:32,477 --> 00:16:36,471
SINCE THE TANK
IS MADE OF PRESSED STEEL.
298
00:16:36,473 --> 00:16:37,673
LIKE ALL M CARS,
299
00:16:37,675 --> 00:16:40,600
THE M6 HAS A TANK
WITH A LARGER CAPACITY
300
00:16:40,602 --> 00:16:42,528
THAN ITS NORMAL 6 COUSIN.
301
00:16:45,366 --> 00:16:47,958
THE CAR RETURNS
TO ITS NORMAL ORIENTATION
302
00:16:47,960 --> 00:16:51,421
FOR THE INSTALLATION
OF THE DASHBOARD.
303
00:16:51,423 --> 00:16:54,157
A LIFT ASSIST HELPS MOVE
THE PREASSEMBLED UNIT
304
00:16:54,159 --> 00:16:56,617
INTO THE CAR'S INTERIOR.
305
00:16:56,619 --> 00:16:58,978
LIKE SO MANY OF
THE M6'S ELEMENTS,
306
00:16:58,980 --> 00:17:01,981
THIS ONE IS ALSO
COMPLETELY CUSTOM-MADE,
307
00:17:01,983 --> 00:17:04,909
FROM THE UPHOLSTERY MATERIALS
AND COLORS
308
00:17:04,911 --> 00:17:07,137
TO THE OPTIONAL
NAVIGATION SYSTEM.
309
00:17:10,242 --> 00:17:11,634
NOW, IT'S TIME
FOR THE MARRIAGE
310
00:17:11,636 --> 00:17:13,636
WHEN THE TWO MAIN
ELEMENTS OF THE CAR,
311
00:17:13,638 --> 00:17:15,462
ITS BODY AND ITS POWER TRAIN,
312
00:17:15,464 --> 00:17:18,566
FINALLY COME TOGETHER
TO CREATE A COMPLETE VEHICLE.
313
00:17:21,529 --> 00:17:23,129
WHILE AN AUTOMATED SYSTEM LIFTS
314
00:17:23,131 --> 00:17:26,324
THE POWER TRAIN
UP INTO THE BODY,
315
00:17:26,326 --> 00:17:27,917
TEAM MEMBERS MANUALLY GUIDE IT
316
00:17:27,919 --> 00:17:30,720
TO ENSURE ACCURATE ALIGNMENT.
317
00:17:30,722 --> 00:17:32,947
THE DRIVERS THEY USE
TO ATTACH THE TWO ELEMENTS
318
00:17:32,949 --> 00:17:35,417
TO EACH OTHER GOVERN
NOT ONLY THE AMOUNT OF TORQUE
319
00:17:35,419 --> 00:17:37,544
THEY APPLY TO EACH SCREW
320
00:17:37,546 --> 00:17:40,138
BUT ALSO THE NUMBER
OF REVOLUTIONS EACH FASTENER
321
00:17:40,140 --> 00:17:44,468
MAKES AS IT GOES IN.
322
00:17:44,470 --> 00:17:45,936
THAT'S BECAUSE,
IF A SCREW'S THREAD
323
00:17:45,938 --> 00:17:48,130
IS DAMAGED,
IT COULD REACH PEAK TORQUE
324
00:17:48,132 --> 00:17:50,766
BEFORE IT'S ACTUALLY TURNED
THE NUMBER OF REVOLUTIONS
325
00:17:50,768 --> 00:17:52,794
REQUIRED TO SINK IT.
326
00:17:55,165 --> 00:17:57,490
HERE, TECHNICIANS
MOUNT THE CAR'S FACE,
327
00:17:57,492 --> 00:18:00,485
MADE OF HIGH-STRENGTH
THERMOPLASTIC COMPOSITE.
328
00:18:00,487 --> 00:18:02,487
THE FRONT END INCLUDES
THE HEADLIGHTS,
329
00:18:02,489 --> 00:18:08,051
BUMPER AND SIGNATURE
BMW KIDNEY-SHAPED GRILLE.
330
00:18:08,053 --> 00:18:09,511
WHILE THE GRILLE
IMMEDIATELY SIGNALS
331
00:18:09,513 --> 00:18:11,313
THAT THE CAR
IS A BMW,
332
00:18:11,315 --> 00:18:16,836
THIS ONE IS UNIQUE
TO THE NEW M6.
333
00:18:16,838 --> 00:18:19,505
ONCE AGAIN EMPHASIZING
ERGONOMIC COMFORT,
334
00:18:19,507 --> 00:18:21,833
THIS STATION FEATURES
SPECIALIZED CHAIRS
335
00:18:21,835 --> 00:18:24,101
TO HELP WITH
THE INSTALLATION PROCESS
336
00:18:24,103 --> 00:18:28,798
AS TECHNICIANS FASTEN
THE COMPONENT IN PLACE.
337
00:18:28,800 --> 00:18:31,259
TEAM MEMBERS BRING THE REAR
BUMPER COVER TO THE CAR
338
00:18:31,261 --> 00:18:32,527
AND FIX IT IN PLACE,
339
00:18:32,529 --> 00:18:35,655
HIDING THE CAR'S REAL BUMPER,
340
00:18:35,657 --> 00:18:36,923
WHICH IS DESIGNED TO ABSORB
341
00:18:36,925 --> 00:18:42,012
THE MAXIMUM ENERGY POSSIBLE
FROM A REAR IMPACT.
342
00:18:42,014 --> 00:18:43,614
WHILE THE M6 COMES STANDARD
343
00:18:43,616 --> 00:18:46,074
WITH 19-INCH
M LIGHT ALLOY WHEELS,
344
00:18:46,076 --> 00:18:48,076
WHICH HAVE SEVEN DOUBLE SPOKES,
345
00:18:48,078 --> 00:18:50,205
THE FIVE DOUBLE SPOKES
ON THIS WHEEL INDICATE
346
00:18:50,207 --> 00:18:52,507
IT'S THE OPTIONAL
20-INCH VERSION.
347
00:18:54,602 --> 00:18:57,403
AFTER A SPECIALIZED
DRIVER RUNS DOWN THE LUGS,
348
00:18:57,405 --> 00:19:02,059
THE INSTANTLY RECOGNIZABLE
BMW LOGO COMPLETES THE ASSEMBLY.
349
00:19:05,230 --> 00:19:07,089
ASIDE FROM THE MARRIAGE
OF THE POWER TRAIN
350
00:19:07,091 --> 00:19:09,758
AND THE BODY, NO POINT
IN THE PRODUCTION PROCESS
351
00:19:09,760 --> 00:19:12,820
IS MORE MOMENTOUS THAN WHEN
A DRIVER STARTS UP A CAR
352
00:19:12,822 --> 00:19:14,113
FOR THE FIRST TIME
353
00:19:14,115 --> 00:19:16,382
AND STEERS IT OFF
THE PRODUCTION LINE.
354
00:19:21,981 --> 00:19:23,440
AT THIS TESTING STATION,
355
00:19:23,442 --> 00:19:25,508
TECHNICIANS USE
HIGH-TECH EQUIPMENT
356
00:19:25,510 --> 00:19:26,968
TO ALIGN THE WHEELS
357
00:19:26,970 --> 00:19:30,464
AND ADJUST
THE HEADLIGHT DIRECTION.
358
00:19:30,466 --> 00:19:32,532
STRIPED LIGHTS
MEASURE THE WHEELS,
359
00:19:32,534 --> 00:19:36,328
ENSURING THE CORRECT ALIGNMENT.
360
00:19:36,330 --> 00:19:38,989
THE DRIVER STAYS OUT
OF THE CAR FOR THIS OPERATION
361
00:19:38,991 --> 00:19:41,058
SO AS NOT TO THROW OFF
THE CAR'S BALANCE.
362
00:19:44,923 --> 00:19:50,684
AFTER ALIGNMENT, A DRIVER TAKES
THE CAR ONTO A ROLLING ROAD.
363
00:19:50,686 --> 00:19:53,479
AT THIS STATION, A MONITOR
READOUT GUIDES THE DRIVER
364
00:19:53,481 --> 00:19:55,015
THROUGH A SERIES OF TESTS
365
00:19:55,017 --> 00:19:59,336
TO MEASURE THE CAR'S
PERFORMANCE DYNAMICS.
366
00:19:59,338 --> 00:20:01,538
FEEDBACK FROM SENSORS
WILL BE COMBINED
367
00:20:01,540 --> 00:20:04,032
WITH THE DRIVER'S
QUALITATIVE RESPONSES
368
00:20:04,034 --> 00:20:08,228
TO SEE WHAT, IF ANYTHING,
NEEDS TO BE FINE-TUNED.
369
00:20:08,230 --> 00:20:11,298
AS HE PUTS THE M
THROUGH ITS PACES,
370
00:20:11,300 --> 00:20:13,025
THE DRIVER PAYS CLOSE ATTENTION
371
00:20:13,027 --> 00:20:15,820
TO THROTTLE RESPONSE,
CLUTCH REACTION,
372
00:20:15,822 --> 00:20:18,356
GEAR SWITCHING
AND ANY UNWANTED NOISES
373
00:20:18,358 --> 00:20:22,452
THAT MIGHT BE GENERATED
BY THE TEST.
374
00:20:22,454 --> 00:20:24,579
HE MUST FOLLOW
THE TESTING SEQUENCES
375
00:20:24,581 --> 00:20:26,848
WITH COMPLETELY
REPEATABLE PRECISION
376
00:20:26,850 --> 00:20:29,042
TO ENSURE THE RESULTS
FOR EACH CAR
377
00:20:29,044 --> 00:20:31,712
CAN BE RELIABLY COMPARED
TO THE BASELINE.
378
00:20:39,671 --> 00:20:41,197
AS A CUSTOMER OPTION,
379
00:20:41,199 --> 00:20:45,793
BMW OFFERS A PAINT
FINISH THEY CALL FROZEN.
380
00:20:45,795 --> 00:20:48,388
UNLIKE TYPICAL SHINY
METALLIC PAINT JOBS,
381
00:20:48,390 --> 00:20:51,390
THIS MATTE SURFACE LENDS THE CAR
A DISTINCTIVE LOOK,
382
00:20:51,392 --> 00:20:56,388
FURTHER ENHANCING
THE VEHICLE'S M CAR DESIGN.
383
00:20:56,390 --> 00:20:58,348
OPEN THE DOOR,
AND THAT DISTINCTIVE
384
00:20:58,350 --> 00:20:59,883
LOOK OF STREAMLINED LUXURY
385
00:20:59,885 --> 00:21:02,611
IS EVIDENT INSIDE
THE M6 AS WELL.
386
00:21:04,773 --> 00:21:08,609
THE REARVIEW CAMERA HIDES
DISCREETLY BEHIND THE BMW BADGE,
387
00:21:08,611 --> 00:21:12,864
WHICH PROTECTS IT
FROM MUD AND GRIME.
388
00:21:12,866 --> 00:21:14,632
WHILE THE POWERFUL V-8
ENGINE CRANKS
389
00:21:14,634 --> 00:21:17,227
OUT 502 FOOT-POUNDS OF TORQUE,
390
00:21:17,229 --> 00:21:22,491
BRINGING THE CAR FROM 0 TO 60
IN JUST 4 SECONDS,
391
00:21:22,493 --> 00:21:26,353
IT'S AT MID-RANGE SPEEDS
THAT THE M6 TRULY SHINES.
392
00:21:26,355 --> 00:21:30,182
THE BMW M6 HANDLES
WITH EQUAL PRECISION
393
00:21:30,184 --> 00:21:32,985
NO MATTER WHAT ROAD
CONDITIONS IT MEETS.
30627
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