1
00:00:09,127 --> 00:00:13,120
NARRATOR: A German factory builds
one of the world's most famous cars.

2
00:00:14,127 --> 00:00:16,482
MAN: The 91 1 is the icon
of the sports car industry.

3
00:00:16,527 --> 00:00:18,677
lt's the shape,
it's the engine in the back,

4
00:00:18,727 --> 00:00:21,480
it's the feeI it gives you,
it's the emotion.

5
00:00:23,887 --> 00:00:26,526
NARRATOR: The factory runs
like a precision machine,

6
00:00:26,567 --> 00:00:29,240
building hundreds of engines a day.

7
00:00:29,287 --> 00:00:30,879
(Man speaks German)

8
00:00:30,927 --> 00:00:34,317
INTERPRETER: The product and
our manufacturing process are one unit,

9
00:00:34,367 --> 00:00:36,437
and that's our secret of success.

10
00:00:37,007 --> 00:00:41,922
NARRATOR: Automation, technology
and skilled human labour

11
00:00:41,967 --> 00:00:45,642
combine to build 1 6 versions
of the Porsche 91 1.

12
00:00:48,407 --> 00:00:51,240
lncluding the 91 1 G T3.

13
00:00:52,007 --> 00:00:53,281
MAN: Lots of our customers,

14
00:00:53,327 --> 00:00:57,161
they want a race car that they can use
on the normaI street as weII.

15
00:00:59,727 --> 00:01:03,037
NARRATOR: The Porsche 91 1 has been made
for more than four decades

16
00:01:03,087 --> 00:01:06,796
on the same grounds
in Stuttgart, Germany,

17
00:01:06,847 --> 00:01:08,838
at Porsche's mega factory.

18
00:01:25,447 --> 00:01:30,760
The Porsche 91 1, small, light, nimble,
and always powered

19
00:01:30,807 --> 00:01:33,924
by a flat six-cylinder engine
in the back of the car.

20
00:01:36,327 --> 00:01:40,320
The 91 1 may offer the ideal connection
between car and driver.

21
00:01:42,287 --> 00:01:45,677
The 91 1 is Iike a gIove
that fits you perfectIy.

22
00:01:45,727 --> 00:01:48,241
The car communicates very directIy
what it's doing,

23
00:01:48,287 --> 00:01:53,122
so it's a very emotionaI driving
experience to have a 91 1 under you.

24
00:01:54,087 --> 00:01:56,840
NARRATOR:
There are 1 6 models of the 91 1.

25
00:02:05,007 --> 00:02:08,158
One of the newest 91 1 s is the G T3.

26
00:02:09,287 --> 00:02:12,563
lt's designed
with one mission in mind.

27
00:02:18,367 --> 00:02:21,882
The GT3 is a track tooI.
It's the uItimate track-day weapon.

28
00:02:26,447 --> 00:02:30,235
NARRATOR: The G T3 is designed for
the growing number of car enthusiasts

29
00:02:30,287 --> 00:02:32,596
who race their cars on closed tracks.

30
00:02:34,087 --> 00:02:37,397
The thrill of owning
your own street-legal racing car

31
00:02:37,447 --> 00:02:40,405
will cost you $ 1 1 2,000.

32
00:02:40,447 --> 00:02:45,840
The G T3's six-cylinder engine
delivers 435 horsepower.

33
00:02:47,047 --> 00:02:53,441
lt catapults the G T3 from 0 to 1 00
kilometres per hour in 4. 1 seconds,

34
00:02:53,487 --> 00:02:57,400
taking it to a top speed
of 31 2 kilometres per hour.

35
00:03:01,887 --> 00:03:04,924
PREUNINGER: lt feels more like
a race car than a street-going car.

36
00:03:04,967 --> 00:03:07,925
ActuaIIy, it's a race car
with a street-IegaI tag on it.

37
00:03:14,927 --> 00:03:18,442
NARRATOR:
Since 1 964, every 91 1 ever built

38
00:03:18,487 --> 00:03:22,241
has been made in Porsche's
mega factory in Stuttgart, Germany.

39
00:03:26,647 --> 00:03:29,241
The factory consists
of several industrial buildings

40
00:03:29,287 --> 00:03:31,278
that are linked together.

41
00:03:32,247 --> 00:03:35,239
The car's body shell
gets its colour in the paint shop.

42
00:03:36,887 --> 00:03:39,845
The 91 1 's famous
flat six-cylinder engine

43
00:03:39,887 --> 00:03:42,196
is built
in the engine assembly building.

44
00:03:44,127 --> 00:03:48,598
Leatherwork for the car's interior
is handcrafted in the upholstery shop.

45
00:03:49,767 --> 00:03:52,235
Finally, all the pieces come together

46
00:03:52,287 --> 00:03:57,566
in the vehicle assembly building
with its 1 1 7 assembly stations.

47
00:04:03,527 --> 00:04:06,599
The factory builds
all 1 6 models of the 91 1,

48
00:04:06,647 --> 00:04:11,084
plus two Porsche Boxster models
on the same assembly line.

49
00:04:14,007 --> 00:04:17,044
INTERPRETER: Every day
we build approximately 40 Boxsters

50
00:04:17,087 --> 00:04:19,396
and about 1 1 0 Porsche 91 1 s.

51
00:04:22,207 --> 00:04:26,041
NARRATOR: The 91 1 's body begins
in the body shell assembly building.

52
00:04:30,567 --> 00:04:35,197
Outside the body shop, stamped
steel body panels are standing by.

53
00:04:39,607 --> 00:04:44,158
lnside, 1 05 robots,
along with teams of skilled welders,

54
00:04:44,207 --> 00:04:46,198
fuse the car's frame together.

55
00:04:49,247 --> 00:04:52,717
The frame is made
of three sub-assemblies..

56
00:04:52,767 --> 00:04:57,318
the front compartment, the mid floor
pan, and the rear compartment.

57
00:05:02,847 --> 00:05:06,681
Each sub-assembly is welded together
from stamped steel parts.

58
00:05:12,327 --> 00:05:15,046
One welder spot-welds
the front compartment of the frame.

59
00:05:17,407 --> 00:05:20,240
While another
works on the rear compartment.

60
00:05:23,167 --> 00:05:27,797
The front compartment is then sent off
to be joined with the rear compartment.

61
00:05:30,687 --> 00:05:35,397
When the mid floor pan is added,
clamps hold the three pieces in place.

62
00:05:37,847 --> 00:05:41,556
Then a robot welds them together,
making them one.

63
00:05:55,767 --> 00:05:58,804
A team of human welders
places a shield between them

64
00:05:58,847 --> 00:06:01,407
to protect against sparks and glare.

65
00:06:03,887 --> 00:06:09,166
They reinforce the job,
welding seams robots cannot reach.

66
00:06:16,687 --> 00:06:20,646
At this point, every 91 1 frame
on the line is identical.

67
00:06:22,527 --> 00:06:25,963
But all that changes
at the geometry station...

68
00:06:30,527 --> 00:06:34,202
..where the various model rear-side
panels are welded onto the vehicle.

69
00:06:35,127 --> 00:06:39,405
Here, the car becomes a hard top
or a convertible cabriolet.

70
00:06:42,687 --> 00:06:45,360
Since this car
is destined to be a hard top,

71
00:06:45,407 --> 00:06:47,557
robots ensure it gets a roof.

72
00:06:54,807 --> 00:06:59,039
When the welding is done, another group
of robots attacks the frame,

73
00:06:59,087 --> 00:07:01,885
this time not to weld but to pierce it.

74
00:07:03,487 --> 00:07:06,479
Hundreds of rivets and screw holes
will allow technicians

75
00:07:06,527 --> 00:07:10,281
to attach components to the body
later in the assembly process.

76
00:07:24,007 --> 00:07:30,401
Next, robots select doors...
and weld door hinges to the frame.

77
00:07:37,887 --> 00:07:43,007
Almost 5,000 welds later, the robotic
work is done in the body shop.

78
00:07:49,047 --> 00:07:51,277
Now workers place
the metal body panels

79
00:07:51,327 --> 00:07:54,603
that give the 91 1
its unmistakeable front shape.

80
00:07:57,767 --> 00:08:00,235
lt starts with the front quarter panels.

81
00:08:03,687 --> 00:08:07,680
And at the next station,
the luggage-compartment cover or bonnet.

82
00:08:16,327 --> 00:08:18,761
Now the body shell is complete.

83
00:08:20,927 --> 00:08:23,122
Even in this raw form,

84
00:08:23,167 --> 00:08:26,716
the body has the iconic shape
of the classic Porsche 91 1.

85
00:08:33,047 --> 00:08:36,676
A shape that has been world famous
for more than 40 years.

86
00:08:40,807 --> 00:08:44,959
MAN: When the 91 1 was launched
for the first time in 1 964,

87
00:08:45,007 --> 00:08:48,397
the design was aImost shocking
or you couId say

88
00:08:48,447 --> 00:08:50,438
very much ahead of the time.

89
00:08:55,367 --> 00:08:59,565
NARRATOR: ln that time, the Porsche 91 1
has seen evolution in its design

90
00:08:59,607 --> 00:09:01,598
but never revolution.

91
00:09:06,247 --> 00:09:09,205
There may be no other car
that has changed so little in appearance

92
00:09:09,247 --> 00:09:11,477
during the course of several decades.

93
00:09:14,807 --> 00:09:18,595
lt may surprise some to learn that
this high-end sports car's beginnings

94
00:09:18,647 --> 00:09:22,959
can be traced to another famous
but much more humble car.

95
00:09:32,927 --> 00:09:36,806
The origins of the Porsche 91 1 's
iconic shape and design

96
00:09:36,847 --> 00:09:39,281
can be sourced to a more modest vehicle.

97
00:09:41,567 --> 00:09:44,161
The Volkswagen Beetle.

98
00:09:44,207 --> 00:09:47,119
And the brilliance of a man
named Ferdinand Porsche.

99
00:09:48,687 --> 00:09:52,919
Ferdinand Porsche was very much ahead
of his time. He was a technicaI genius.

100
00:09:56,647 --> 00:09:59,798
NARRATOR: Ferdinand Porsche
was a self-taught automotive designer

101
00:09:59,847 --> 00:10:02,361
and engineer.

102
00:10:02,407 --> 00:10:05,638
ln 1 900, at the age of 25,

103
00:10:05,687 --> 00:10:08,997
he had designed the world's
first hybrid petrol/electric car

104
00:10:09,047 --> 00:10:11,038
for an Austrian company.

105
00:10:12,727 --> 00:10:16,640
He also spent more than a decade
designing cars for Mercedes.

106
00:10:19,967 --> 00:10:23,880
By the 1 930s, Ferdinand Porsche
had formed his own company

107
00:10:23,927 --> 00:10:26,236
designing cars for other manufacturers.

108
00:10:28,327 --> 00:10:32,240
He sold the German government
on his dream of a small, simple car

109
00:10:32,287 --> 00:10:34,642
that would be affordable to the masses.

110
00:10:37,807 --> 00:10:40,924
That car eventually became
the Volkswagen Beetle.

111
00:10:46,047 --> 00:10:49,756
After World War ll,
Ferdinand Porsche's son, Ferry Porsche,

112
00:10:49,807 --> 00:10:51,798
took control of the company.

113
00:10:54,167 --> 00:10:58,046
Ferry Porsche wanted a sports car
not for the general public

114
00:10:58,087 --> 00:11:00,317
but for his own driving pleasure.

115
00:11:05,287 --> 00:11:07,847
A post-war shortage of parts
forced Ferry Porsche

116
00:11:07,887 --> 00:11:11,118
to use components
from the Volkswagen Beetle.

117
00:11:12,807 --> 00:11:16,322
The rear-mounted, air-cooled,
four-cylinder engine,

118
00:11:16,367 --> 00:11:19,404
the gearbox and the suspension.

119
00:11:19,447 --> 00:11:22,644
Ferry Porsche modified everything
to make it more sporty.

120
00:11:25,247 --> 00:11:29,923
NARRATOR.. The car that emerged in 1 948
was the Porsche 356.

121
00:11:32,087 --> 00:11:36,080
More than 75,000 were made
over the course of 1 5 years.

122
00:11:38,047 --> 00:11:41,005
lt was the first sports car
to bear the Porsche name.

123
00:11:48,767 --> 00:11:53,716
ln the late 1 950s,
Ferry Porsche wanted a new sports car.

124
00:11:57,007 --> 00:12:01,205
This time he insisted
on a more powerful six-cylinder engine.

125
00:12:05,287 --> 00:12:07,642
For the new car's physical design,

126
00:12:07,687 --> 00:12:12,283
Ferry Porsche turned to his oldest son,
known as Butzi Porsche.

127
00:12:12,327 --> 00:12:16,718
He reaIised the perfect successor
of the Porsche 356

128
00:12:16,767 --> 00:12:21,238
because he uses
the cIassic design Iine of the car,

129
00:12:21,287 --> 00:12:24,245
but he moved it in a very forward way.

130
00:12:27,167 --> 00:12:33,640
NARRATOR: The result was presented in
1 963 and eventually was called the 91 1.

131
00:12:36,047 --> 00:12:40,962
Over the course of four decades,
the design was updated just five times,

132
00:12:41,007 --> 00:12:44,283
resulting in six generations of 91 1 s.

133
00:12:45,207 --> 00:12:50,486
I think the design carries on because
Porsche aIways understood very weII

134
00:12:50,527 --> 00:12:55,806
what you have to do to bring
the 91 1 design language into the future.

135
00:13:03,927 --> 00:13:05,838
NARRATOR.. Now the unpainted body shells,

136
00:13:05,887 --> 00:13:09,436
descended from the first 91 1 s
built in 1 964,

137
00:13:09,487 --> 00:13:12,479
are ready to leave the body shop
to be painted.

138
00:13:14,167 --> 00:13:17,284
The trouble is,
the body shop and the paint shop

139
00:13:17,327 --> 00:13:19,761
have a four-lane road separating them.

140
00:13:21,087 --> 00:13:26,241
So how does the body shell move
from the body shop to the paint shop?

141
00:13:26,287 --> 00:13:27,276
A bridge.

142
00:13:28,847 --> 00:13:32,965
This bridge is going over one of
the most used streets in Stuttgart.

143
00:13:34,687 --> 00:13:36,996
NARRATOR: lt takes
about half an hour for a body shell

144
00:13:37,047 --> 00:13:40,437
to travel 86 metres over the bridge
to the paint shop.

145
00:13:49,527 --> 00:13:54,123
The paint shop's first step is
a car wash that removes dirt and grease.

146
00:13:55,687 --> 00:14:00,397
Bodies are then blow-dried
to remove any lingering dust.

147
00:14:02,887 --> 00:14:05,720
Once the surface is clinically clean...

148
00:14:07,767 --> 00:14:11,646
..it heads into a paint bath
containing 60 cubic metres of paint.

149
00:14:15,887 --> 00:14:20,005
The bath holds an anticorrosion paint
called cathodic dip primer.

150
00:14:22,207 --> 00:14:25,517
The cathodic dip primer
is electrically charged positive.

151
00:14:26,847 --> 00:14:30,635
The metal carrier that holds the car
carries a negative charge.

152
00:14:31,487 --> 00:14:35,036
As the car is submerged,
the carrier agitates the car,

153
00:14:35,087 --> 00:14:37,442
making sure the positively charged paint

154
00:14:37,487 --> 00:14:40,923
is drawn to every part
of the negatively charged body.

155
00:14:42,247 --> 00:14:44,078
When the car emerges from the bath,

156
00:14:44,127 --> 00:14:46,800
the bond of the paint is so strong

157
00:14:46,847 --> 00:14:49,600
that excess paint
can be washed off with water.

158
00:14:55,727 --> 00:14:58,400
Now the car heads into a dryer
for 30 minutes

159
00:14:58,447 --> 00:15:00,324
to cure the cathodic dipped paint.

160
00:15:12,927 --> 00:15:16,044
A single speck of dust
can ruin a paint job,

161
00:15:16,087 --> 00:15:20,000
which is why technicians dust the body
before the primer coat.

162
00:15:23,967 --> 00:15:27,516
The interior of the car
is primed by human painters.

163
00:15:34,847 --> 00:15:37,680
The exterior
is where the robots take over.

164
00:15:39,807 --> 00:15:42,321
The primer
is electrically charged positive.

165
00:15:42,367 --> 00:15:45,677
As the robots atomise the paint
into the air,

166
00:15:45,727 --> 00:15:49,083
the paint is attracted to the car's
negatively charged surface.

167
00:15:51,247 --> 00:15:54,239
lt may look like the colour coat,
but it's not.

168
00:15:54,287 --> 00:15:57,165
The primer can be one of five colours..

169
00:15:57,207 --> 00:16:01,962
white, light grey, dark grey,
yellow or red.

170
00:16:04,287 --> 00:16:09,281
The selected primer colour
is the closest match to the colour coat.

171
00:16:10,887 --> 00:16:12,559
With the primer complete,

172
00:16:12,607 --> 00:16:17,317
the car heads into the
1 70-degree-Celsius dryer for 30 minutes.

173
00:16:21,807 --> 00:16:25,243
Now it's time for the car
to get its colour coat.

174
00:16:25,287 --> 00:16:30,919
INTERPRETER: The most popular colours
for a Porsche are black, white, red.

175
00:16:32,567 --> 00:16:36,879
NARRATOR.. Porsche offers 1 2 standard
colours, plus nine premium colours.

176
00:16:40,207 --> 00:16:44,837
But for a fee, Porsche will custom paint
your car any colour you want.

177
00:16:52,007 --> 00:16:54,646
Because of the number of colours
offered by the factory,

178
00:16:54,687 --> 00:16:57,121
the colour coat is painted by hand.

179
00:17:03,527 --> 00:17:08,123
ln all, four to five litres of paint
are applied, depending on the colour.

180
00:17:10,007 --> 00:17:11,679
With the colour coat complete,

181
00:17:11,727 --> 00:17:16,881
the 91 1 heads into a 1 60-degree-Celsius
dryer to cure the paint.

182
00:17:23,527 --> 00:17:26,883
The final layer
is a solvent-based clear coat.

183
00:17:26,927 --> 00:17:29,157
The clear coat is painted by robots

184
00:17:29,207 --> 00:17:32,244
because the same clear coat
is used for every car.

185
00:17:35,247 --> 00:17:38,125
The robot is also programmed
to open the doors of the car

186
00:17:38,167 --> 00:17:40,123
and coat the interior surfaces.

187
00:17:46,527 --> 00:17:48,279
The paint shop's final job

188
00:17:48,327 --> 00:17:50,921
is putting the Porsche logo
on the vehicle's bonnet.

189
00:18:07,207 --> 00:18:09,038
ln all, it takes eight hours

190
00:18:09,087 --> 00:18:14,719
for a 91 1 to enter the paint shop
as a steel shell and exit a painted car.

191
00:18:22,487 --> 00:18:26,605
Now preparations are underway to build
the vehicle's six-cylinder heart.

192
00:18:42,047 --> 00:18:45,164
From the very beginning, since 1 964,

193
00:18:45,207 --> 00:18:50,042
the heart of the Porsche 91 1
has always been a six-cylinder engine.

194
00:18:52,807 --> 00:18:55,640
But not just any six-cylinder engine.

195
00:18:58,087 --> 00:19:01,636
Six-cylinder engines
come in three major types.

196
00:19:01,687 --> 00:19:03,837
Some are straight sixes.

197
00:19:03,887 --> 00:19:07,675
The most common six-cylinder engines
are V6s.

198
00:19:07,727 --> 00:19:13,120
The Porsche 91 1 has always used
an engine known as a flat six-cylinder,

199
00:19:13,167 --> 00:19:17,080
with two rows of three cylinders
horizontally opposed to each other.

200
00:19:23,767 --> 00:19:27,282
Porsche believes there is
a key advantage to the flat six design

201
00:19:27,327 --> 00:19:29,477
when used in its sports cars.

202
00:19:31,127 --> 00:19:36,042
The biggest advantage of using
a fIat six-cyIinder in the Porsche 91 1

203
00:19:36,087 --> 00:19:38,123
is its Iow centre of gravity.

204
00:19:38,167 --> 00:19:41,842
Because it's very small,
you can mount it down low in the body.

205
00:19:47,247 --> 00:19:50,842
NARRATOR: The lower centre of gravity
contributes to improved handling.

206
00:19:53,767 --> 00:19:57,077
The Iower the centre of gravity is,

207
00:19:57,127 --> 00:19:59,800
the more stabIe the car is
at high speeds and the cornering.

208
00:20:07,967 --> 00:20:10,527
NARRATOR:
Those famous flat six-cylinder engines

209
00:20:10,567 --> 00:20:13,206
are made
in the factory's engine assembly area.

210
00:20:16,327 --> 00:20:18,557
(Man speaks German)

211
00:20:18,607 --> 00:20:22,759
INTERPRETER: ln Stuttgart, we build in
total approximately 500 engines per day.

212
00:20:26,407 --> 00:20:30,195
NARRATOR: Every three minutes,
the plant completes a flat six engine.

213
00:20:37,887 --> 00:20:40,242
The plant makes
more than 20 different versions

214
00:20:40,287 --> 00:20:42,642
of its flat six-cylinder engine,

215
00:20:42,687 --> 00:20:47,317
ranging from 255 to 535 horsepower.

216
00:20:50,167 --> 00:20:52,442
Each version
of the flat six-cylinder engine

217
00:20:52,487 --> 00:20:55,081
has many of its own specific parts.

218
00:20:59,767 --> 00:21:02,964
The challenge is getting the right parts
to the right place

219
00:21:03,007 --> 00:21:05,316
just in time for the engine's assembly.

220
00:21:07,367 --> 00:21:10,279
So Porsche developed
an automated logistics system.

221
00:21:13,967 --> 00:21:16,720
Engine parts are loaded onto a cart.

222
00:21:19,407 --> 00:21:24,083
The cart is then picked up by Porsche's
patented driverless transport system.

223
00:21:28,407 --> 00:21:32,685
Carts are programmed to take a specific
route to the engine assembly area.

224
00:21:33,367 --> 00:21:37,679
The route takes them over a bridge
and into an lift,

225
00:21:37,727 --> 00:21:39,763
where they go down one floor

226
00:21:39,807 --> 00:21:43,686
and deliver the parts to
the engine assembly area just in time.

227
00:21:50,207 --> 00:21:53,199
The factory has a total of 21 carts.

228
00:21:53,247 --> 00:21:56,637
Nine of the carts are dedicated
to removing completed engines

229
00:21:56,687 --> 00:21:58,803
from the engine assembly area.

230
00:21:58,847 --> 00:22:02,999
The carts take the finished engines
back up to the logistics area.

231
00:22:04,047 --> 00:22:08,643
But how do the carts know where to go
and which path to take?

232
00:22:08,687 --> 00:22:10,803
(Man speaks German)

233
00:22:11,567 --> 00:22:14,684
INTERPRETER: Every five metres we have
magnets embedded in the floor

234
00:22:14,727 --> 00:22:16,957
which are covered by concrete,

235
00:22:17,007 --> 00:22:20,443
and between one five metre distance
and the next five metres,

236
00:22:20,487 --> 00:22:22,284
the cart is programmed to find its way.

237
00:22:22,327 --> 00:22:24,716
This, for example, is such a spot.

238
00:22:27,487 --> 00:22:30,797
NARRATOR: Each cart
travels 20 kilometres every day

239
00:22:30,847 --> 00:22:33,805
at speeds
of over five kilometres per hour.

240
00:22:35,767 --> 00:22:39,442
The people on the floor seem to know
how to stay out of the cart's way,

241
00:22:39,487 --> 00:22:41,796
but, just in case, there are safeguards.

242
00:22:44,767 --> 00:22:46,917
(Speaks German)

243
00:22:46,967 --> 00:22:50,164
INTERPRETER: Nothing happens,
even though it's carrying a heavy load

244
00:22:50,207 --> 00:22:52,323
and these carts move
at quite a high speed.

245
00:22:52,367 --> 00:22:56,883
Nothing can happen because we have
a built-in safety system in there.

246
00:23:04,287 --> 00:23:07,040
NARRATOR:
For every flat six-cylinder engine made,

247
00:23:07,087 --> 00:23:10,204
there are three parts deliveries
to the assembly floor.

248
00:23:13,967 --> 00:23:17,277
The first parts delivery
is pushed by hand.

249
00:23:17,327 --> 00:23:21,639
lt contains both halves of the
crankcase, the crankshaft and pistons.

250
00:23:33,687 --> 00:23:36,565
Early in the line,
pistons are assembled.

251
00:23:36,607 --> 00:23:40,077
Then the first three pistons
are carefully put into the crankcase.

252
00:23:45,487 --> 00:23:50,277
Then the crankshaft is placed
into one of the crankcase halves.

253
00:23:54,487 --> 00:23:58,116
That first row of pistons
is linked to the crankshaft.

254
00:23:59,727 --> 00:24:04,437
Then a robot installs the second half
of the crankcase and bolts it on.

255
00:24:08,407 --> 00:24:10,557
Now the partially assembled engine

256
00:24:10,607 --> 00:24:13,121
travels to the main
engine assembly line.

257
00:24:15,327 --> 00:24:21,482
Meeting that partially assembled engine,
a special carrier called a cross member.

258
00:24:21,527 --> 00:24:24,325
The cross member allows technicians
to manoeuvre the engine

259
00:24:24,367 --> 00:24:26,358
for easier assembly.

260
00:24:33,127 --> 00:24:36,517
(Speaks German)

261
00:24:36,567 --> 00:24:39,604
INTERPRETER: You can rotate the engine,
lift and lower the engine,

262
00:24:39,647 --> 00:24:44,277
so that the workman always works
in an optimal ergonomic position.

263
00:24:48,007 --> 00:24:49,599
NARRATOR: Two stations down,

264
00:24:49,647 --> 00:24:52,081
a technician puts
the cross member to work,

265
00:24:52,127 --> 00:24:54,118
flipping the engine on its side

266
00:24:54,167 --> 00:24:56,965
and installing the remaining
three piston heads.

267
00:25:00,487 --> 00:25:02,205
The technician cranks the engine

268
00:25:02,247 --> 00:25:05,523
to check the piston linkages
with the crankshaft,

269
00:25:05,567 --> 00:25:07,922
ensuring the operation is smooth.

270
00:25:11,727 --> 00:25:15,959
Next, a cylinder head is placed
onto one side of the engine.

271
00:25:16,007 --> 00:25:17,884
The cylinder head contains valves

272
00:25:17,927 --> 00:25:21,556
that will let air into the cylinders
and take exhaust out.

273
00:25:25,407 --> 00:25:28,160
Technicians put the cross member
to work again,

274
00:25:28,207 --> 00:25:32,280
flipping the engine so the other
cylinder head can be installed.

275
00:25:40,247 --> 00:25:45,162
Every two minutes and 44 seconds,
the engine reaches a new station.

276
00:25:47,807 --> 00:25:50,480
Some stations are manned
by human beings.

277
00:25:53,767 --> 00:25:56,042
Others are handled by robots.

278
00:25:58,487 --> 00:26:00,318
(WiII speaks German)

279
00:26:00,367 --> 00:26:02,835
INTERPRETER:
Automation makes sense in those places

280
00:26:02,887 --> 00:26:04,525
where many things are repeated.

281
00:26:04,567 --> 00:26:07,161
lf you screw 20 screws into an oil pan,

282
00:26:07,207 --> 00:26:10,961
it's not necessary
that one employee screws in 20 screws.

283
00:26:11,007 --> 00:26:15,000
A robot can do that.
That doesn't achieve any added value.

284
00:26:15,047 --> 00:26:18,835
But if you have complex assembly
procedures, you need the employee.

285
00:26:24,807 --> 00:26:27,480
NARRATOR: About two thirds of the way
through the line,

286
00:26:27,527 --> 00:26:30,803
every engine goes through
what's known as a cold test.

287
00:26:33,967 --> 00:26:37,243
Here the engine
is electrically cranked and turned.

288
00:26:37,287 --> 00:26:40,597
lts linkages and systems
are checked by computer.

289
00:26:45,527 --> 00:26:49,281
After the test,
the intake manifold is installed.

290
00:26:51,407 --> 00:26:54,399
The engine will breathe in its air
through these plastic tubes.

291
00:26:57,887 --> 00:27:01,277
The engine exhales
through the exhaust manifold,

292
00:27:01,327 --> 00:27:03,966
the last major part installed.

293
00:27:08,287 --> 00:27:12,678
One in every hundred engines
is plucked from the line for a hot test,

294
00:27:12,727 --> 00:27:15,116
in which the engine
is fired up with petrol.

295
00:27:27,887 --> 00:27:32,836
lt's taken about six hours to build the
flat six engine from start to finish.

296
00:27:44,807 --> 00:27:46,206
At the end of the line,

297
00:27:46,247 --> 00:27:49,683
completed engines are taken away
by the driverless transport carts

298
00:27:49,727 --> 00:27:51,718
and delivered to a holding area.

299
00:27:53,247 --> 00:27:56,045
They'll eventually be taken
to the main assembly line

300
00:27:56,087 --> 00:27:58,237
and married to the vehicle's body.

301
00:28:05,567 --> 00:28:08,684
At Porsche's mega factory
in Stuttgart, Germany,

302
00:28:08,727 --> 00:28:12,766
the assembly line puts together
1 6 different models of the 91 1.

303
00:28:18,327 --> 00:28:22,161
Each 91 1 will spend about 1 5 hours
moving down the line.

304
00:28:25,727 --> 00:28:28,844
The line has 1 1 7 assembly stations.

305
00:28:32,247 --> 00:28:36,718
Workers at each station have just over
five minutes to complete their tasks

306
00:28:36,767 --> 00:28:38,962
before the next car moves into place.

307
00:28:42,527 --> 00:28:45,564
But as they work,
the line does not stop.

308
00:28:49,767 --> 00:28:51,803
(Man speaks German)

309
00:28:51,847 --> 00:28:53,963
INTERPRETER:
The line is moving continuously

310
00:28:54,007 --> 00:28:57,966
so the technicians can keep working
and don't have to stop during the feed.

311
00:29:01,927 --> 00:29:05,806
NARRATOR: Now a painted body shell
enters the main assembly line.

312
00:29:07,207 --> 00:29:09,198
Station one.

313
00:29:10,287 --> 00:29:13,643
The 91 1 's new paint job
is protected with pads.

314
00:29:16,247 --> 00:29:20,001
Then the doors come off to allow easier
access to the inside of the car

315
00:29:20,047 --> 00:29:22,038
throughout the assembly process.

316
00:29:24,287 --> 00:29:28,565
At station two, technicians
snake wiring through the car,

317
00:29:28,607 --> 00:29:31,838
laying down the network
for the electrical system.

318
00:29:33,687 --> 00:29:34,836
Station six.

319
00:29:34,887 --> 00:29:38,516
The first upholstered item
is put in the car, the cockpit,

320
00:29:38,567 --> 00:29:40,558
which includes the leather dash.

321
00:29:45,807 --> 00:29:50,437
At Porsche, leather begins as tanned
cow hides in the upholstery shop.

322
00:29:56,207 --> 00:29:59,722
The basic 91 1 has 40 upholstered pieces,

323
00:29:59,767 --> 00:30:03,396
including the dash,
door panels and seats.

324
00:30:06,087 --> 00:30:09,921
lt takes six hides
to upholster an average 91 1.

325
00:30:21,567 --> 00:30:23,364
Hides are laid out on a machine

326
00:30:23,407 --> 00:30:26,479
that automatically cuts the pieces
to be upholstered,

327
00:30:26,527 --> 00:30:28,836
while avoiding flaws in the leather.

328
00:30:37,167 --> 00:30:41,206
The machine uses a powerful waterjet
to cut the leather.

329
00:30:41,887 --> 00:30:45,675
The pressure coming out of the nozzle
is 3,000 bar,

330
00:30:45,727 --> 00:30:49,561
about 30 times the pressure of
a power washer used to clean buildings.

331
00:30:54,407 --> 00:30:57,797
The machine is done
and now the pieces are collected.

332
00:31:02,487 --> 00:31:06,366
The first workers to get their hands
on the cut leather are the sewers,

333
00:31:06,407 --> 00:31:08,398
who stitch pieces together.

334
00:31:15,127 --> 00:31:18,802
Next, a robot sprays
the stitched leather with glue.

335
00:31:25,487 --> 00:31:28,320
Then a craftsperson
has the painstaking task

336
00:31:28,367 --> 00:31:31,279
of fitting the leather
to the dashboard frame.

337
00:31:32,887 --> 00:31:36,038
Heat makes the leather
more pliable and workable.

338
00:31:36,087 --> 00:31:38,555
lt also keeps the glue tacky.

339
00:31:41,207 --> 00:31:44,995
The first challenge is fitting the seam
in the frame's groove.

340
00:31:49,367 --> 00:31:52,962
Then the leather has to be stretched
over the top of the dash.

341
00:31:55,407 --> 00:31:59,446
Once the fit is right, he trims
the excess leather with a knife...

342
00:32:02,007 --> 00:32:05,124
..and rounds the remaining material
under the dash.

343
00:32:06,687 --> 00:32:11,238
A little pressure with a sand-filled
weight smoothes out any ripples

344
00:32:11,287 --> 00:32:13,960
and completes the job
an hour after it began.

345
00:32:19,687 --> 00:32:23,396
The upholstered dashboards
are sent to a pre-assembly area,

346
00:32:23,447 --> 00:32:26,041
just a few yards
from the main assembly line.

347
00:32:28,847 --> 00:32:32,396
Here, they are built up
into full cockpit assemblies,

348
00:32:32,447 --> 00:32:34,756
including gauges and steering columns.

349
00:32:41,847 --> 00:32:46,762
Once assembled, the cockpit is the first
upholstered piece installed on the car.

350
00:32:53,407 --> 00:32:55,875
Six assembly stations are complete.

351
00:32:55,927 --> 00:32:58,964
The car'sjourney down the line
isjust beginning,

352
00:32:59,007 --> 00:33:02,238
with the most challenging
assembly processes ahead.

353
00:33:16,607 --> 00:33:19,485
Porsche's mega 91 1 factory
in Stuttgart, Germany,

354
00:33:19,527 --> 00:33:22,405
has 1 1 7 assembly stations.

355
00:33:29,207 --> 00:33:32,005
Down the line, at station 1 8,

356
00:33:32,047 --> 00:33:35,756
the assembly area's only robot
installs the windscreen.

357
00:33:35,807 --> 00:33:39,402
First, it applies glue
to the inside of the glass.

358
00:33:43,087 --> 00:33:47,046
This robot works in the dark
because of its infrared sensors,

359
00:33:47,087 --> 00:33:51,558
which help it position the windscreen
to tolerances within half a millimetre.

360
00:33:56,087 --> 00:33:57,759
Station 30.

361
00:34:00,487 --> 00:34:05,436
lf the 91 1 coming down the line
is a G T3,

362
00:34:05,487 --> 00:34:09,082
this is where technicians install
the prominent rear wing.

363
00:34:12,167 --> 00:34:17,366
Aeroplanes use wings to create lift,
enabling the aircraft to fly.

364
00:34:19,167 --> 00:34:24,161
The G T3's wing is angled
to do the opposite,

365
00:34:24,207 --> 00:34:26,038
to keep the car on the ground.

366
00:34:28,727 --> 00:34:31,116
The faster a car goes,
the more Iift it creates,

367
00:34:31,167 --> 00:34:34,523
and we have to overcome that Iift and
push the car down on the street again,

368
00:34:34,567 --> 00:34:37,559
because that's what
makes the car controIIabIe.

369
00:34:42,687 --> 00:34:46,396
NARRATOR: Just a few stations
down the line, station 34,

370
00:34:46,447 --> 00:34:50,679
the name of the 91 1 model
is spelled out for the world to see.

371
00:34:52,607 --> 00:34:56,805
Special guides hold the letters in place
so they can be stuck onto the car.

372
00:35:06,127 --> 00:35:10,723
Every car moving down the line
is destined to be different.

373
00:35:10,767 --> 00:35:14,157
Each is built
for a specific customer order,

374
00:35:14,207 --> 00:35:16,198
with a unique set of options.

375
00:35:19,207 --> 00:35:22,244
That means different cars
need different parts.

376
00:35:23,927 --> 00:35:25,485
Like the engine line,

377
00:35:25,527 --> 00:35:29,202
the main assembly line also uses
a driverless transport system

378
00:35:29,247 --> 00:35:32,319
to bring parts to stations
just when they're needed.

379
00:35:35,167 --> 00:35:37,965
But these carts
use a visual tracking system

380
00:35:38,007 --> 00:35:40,282
to follow a black stripe on the floor.

381
00:35:43,607 --> 00:35:48,362
The problem is,
the line is constantly moving,

382
00:35:48,407 --> 00:35:51,240
threatening to leave the cart
and its parts behind.

383
00:35:54,047 --> 00:35:57,960
The solution is simple,
to link the carts to the moving line.

384
00:36:02,967 --> 00:36:05,800
Two stations down, at station 55...

385
00:36:10,407 --> 00:36:13,285
Two of those parts on a cart
are the radiators.

386
00:36:21,287 --> 00:36:25,519
The 91 1 's two radiators
are installed in front of the car.

387
00:36:26,607 --> 00:36:30,919
Hoses cycle coolant to the rear,
where the engine will be located.

388
00:36:36,207 --> 00:36:39,995
The engine that those radiators
will cool arrives on the assembly floor

389
00:36:40,047 --> 00:36:42,038
near the halfway point on the line.

390
00:36:47,847 --> 00:36:51,806
Technicians connect the engine
and transmission to a pre-assembly

391
00:36:51,847 --> 00:36:55,237
that also includes the suspension,
brakes and axles.

392
00:37:02,887 --> 00:37:06,641
lt's all in advance of
the most dramatic moment on the line,

393
00:37:06,687 --> 00:37:09,485
the marriage
of the power train and body.

394
00:37:19,447 --> 00:37:23,645
The Porsche 91 1 is famous
for both its iconic shape

395
00:37:23,687 --> 00:37:26,838
and its rear-mounted
flat six-cylinder engine.

396
00:37:32,007 --> 00:37:35,841
Now, at Porsche's mega factory
in Stuttgart, Germany,

397
00:37:35,887 --> 00:37:40,836
that body and engine are about to come
together midway down the assembly line,

398
00:37:40,887 --> 00:37:43,196
at station 61.

399
00:37:47,687 --> 00:37:52,044
The joining of the body and power train
assembly is called a marriage.

400
00:37:52,087 --> 00:37:54,442
lt's a major moment on the line.

401
00:37:58,647 --> 00:38:01,764
The entire car that's been built up
coming down the line

402
00:38:01,807 --> 00:38:05,083
is now bolted
to the suspension and power train.

403
00:38:06,287 --> 00:38:10,485
Even so,
it's like any other station on the line.

404
00:38:10,527 --> 00:38:14,122
Technicians must accomplish the task
in about five minutes.

405
00:38:31,767 --> 00:38:36,761
The 91 1 's engine is in place, although
many would say in an unusual place.

406
00:38:38,847 --> 00:38:43,045
lt's one of the few cars made today
with an engine mounted in the rear.

407
00:38:47,927 --> 00:38:51,124
PREUNINGER: The main advantage of having
an engine in the rear of the car

408
00:38:51,167 --> 00:38:52,236
is the traction.

409
00:38:52,287 --> 00:38:55,404
Because the engine sits
right on top of the driven wheeI,

410
00:38:55,447 --> 00:38:58,803
it gives you a Iot of traction so you
can put a Iot of power to the street

411
00:38:58,847 --> 00:39:02,886
without having to fear for wheel spins,
which is not efficient.

412
00:39:10,927 --> 00:39:13,566
NARRATOR:
Back on the line at station 77.

413
00:39:13,607 --> 00:39:17,759
The 91 1 may have left the body shop
almost 1 7 hours ago,

414
00:39:17,807 --> 00:39:20,480
but it's only now
that the body is finished

415
00:39:20,527 --> 00:39:24,361
by adding the bumpers, front and rear.

416
00:39:28,807 --> 00:39:31,196
Technicians also add the tail-lights.

417
00:39:44,007 --> 00:39:45,963
Station 83.

418
00:39:46,007 --> 00:39:47,838
Signs the end of the line is nearing

419
00:39:47,887 --> 00:39:51,596
as fluids for air conditioning, brakes
and power steering are added.

420
00:39:59,967 --> 00:40:04,006
But if the end is near,
the car will need its wheels and tyres.

421
00:40:05,287 --> 00:40:06,925
They're at station 98.

422
00:40:11,487 --> 00:40:14,684
Tyres are fitted to the wheels
just before installation.

423
00:40:18,047 --> 00:40:21,244
All five lug nuts are torqued at once.

424
00:40:23,927 --> 00:40:29,559
Unless it's a 91 1 G T3.
lts wheels use a special centre lock.

425
00:40:32,447 --> 00:40:35,439
The centre-lock system
is used on racing cars

426
00:40:35,487 --> 00:40:38,399
because it allows
for faster tyre changes.

427
00:40:39,847 --> 00:40:43,317
Porsche is the first company
that offers the centre-Iock wheeI

428
00:40:43,367 --> 00:40:44,561
on a street-IegaI car.

429
00:40:45,967 --> 00:40:47,878
NARRATOR:
The factory uses a special tool

430
00:40:47,927 --> 00:40:50,999
just to torque the centre locks
on G T3 wheels.

431
00:41:01,207 --> 00:41:06,440
With wheels in place, the cars
seem ready to roll, but not quite.

432
00:41:09,327 --> 00:41:12,239
At the next station down, station 99,

433
00:41:12,287 --> 00:41:15,040
the hard tops
get their rear side window.

434
00:41:17,487 --> 00:41:20,923
Something the 91 1 has had since 1 964.

435
00:41:26,367 --> 00:41:30,645
lf the car heading into station 1 03
is a cabriolet,

436
00:41:30,687 --> 00:41:35,203
it's still missing one crucial piece,
the soft top.

437
00:41:37,767 --> 00:41:43,046
The 91 1 cabriolet's soft top
opens and closes in just 20 seconds.

438
00:41:46,287 --> 00:41:49,245
The end of the line is approaching.

439
00:41:51,687 --> 00:41:53,678
Station 1 1 0.

440
00:41:54,607 --> 00:41:57,644
The doors that came off
at the very beginning of the line

441
00:41:57,687 --> 00:41:59,678
now get put back on.

442
00:42:12,007 --> 00:42:18,242
And at station 1 1 3, workers install the
last major parts, the upholstered seats.

443
00:42:28,807 --> 00:42:32,243
Now the car is fuelled
with more than 1 8 litres of petrol.

444
00:42:36,047 --> 00:42:38,561
Then it's started for the first time.

445
00:42:42,167 --> 00:42:45,000
The first roll test
simulates a bumpy road.

446
00:42:54,487 --> 00:42:59,766
Then another roll test takes the car
up to speeds of 1 20 kilometres per hour.

447
00:43:13,487 --> 00:43:16,877
The final inspection
takes about two hours.

448
00:43:16,927 --> 00:43:19,122
Then the cars leave the factory.

449
00:43:28,487 --> 00:43:31,524
A transporter will now take them
to a shipping depot

450
00:43:31,567 --> 00:43:35,401
where they'll eventually end up
at dealerships around the world.

451
00:43:40,767 --> 00:43:42,564
For more than 40 years,

452
00:43:42,607 --> 00:43:47,203
Porsche's Stuttgart factory has been
turning out cars with this iconic shape.

453
00:43:53,407 --> 00:43:55,523
Just as the 91 1 has evolved,

454
00:43:55,567 --> 00:43:58,479
so have the factory's
manufacturing processes.

455
00:44:09,127 --> 00:44:13,643
But if workers from the past could see
almost half a century into the future,

456
00:44:13,687 --> 00:44:17,362
they might be surprised
to find today's workers building a car

457
00:44:17,407 --> 00:44:19,637
that looks remarkably similar.

458
00:44:25,887 --> 00:44:28,765
Any generation of workers
on the production line

459
00:44:28,807 --> 00:44:30,604
can take pride knowing they have built

460
00:44:30,647 --> 00:44:32,763
one of the world's most famous
sports cars

461
00:44:32,807 --> 00:44:34,798
more than 40 years running.

462
00:44:38,767 --> 00:44:44,046
Porsche's factory in Stuttgart, Germany,
is a mega factory.