Porsche: High-Level Car Manufacturer | Mega Manufacturing | Free Documentary

[Music] the Porsche Macan a compact SUV combining off-road qualities and everyday versatility with the DNA of a sports car in this plant four thousand three hundred employees produce over 90,000 makan vehicles per year every single vehicle absolutely individual and bespoke manufactured to order [Music] a masterpiece of logistics and engineering design it's mega manufacturing with ultimate passion and absolute precision [Music] the pushy makan the most successful horse and the stable of this legendary sports car manufacturer the makan is available starting at around sixty thousand euros was several extras however the price tag quickly grows to more than one hundred thousand in the turbo version the makan goes 440 horsepower acceleration from 0 to 100 km/h and only 4.5 seconds its top speed is around 270 km/h the makan is built near Leipzig in eastern Germany production is divided up into three halls on more than 145,000 square meters in the body shop the paint shop and in final assembly but this is where it all begins in the body shop the birthplace of the Porsche Macan on more than 35,000 square meters robots and people turn pure sheet metal into sub frames around the clock the robots are in temporal l production lines they can change their tool heads within seconds inserting various screws or placing welding points adapting on the spot to the demands of the car and customer eight hours is all they need for the entire production of a fully galvanized aluminum steel car body production manager hemming steinborn is responsible for ensuring that everything runs smoothly here the major challenge perfectly aligning all the different elements engineering people and material ensuring there's a perfect balance between quality and unit quantities retaining their outstanding quality and delivering volume a balancing act for premium manufacturers like Porsche here we have four hundred robots all together every day they make four hundred car bodies out of four hundred individual parts the whole thing doesn't work without employees we have 400 employees and working throughout a 24 hour a day keep body manufacturing up and running the subframe of the Porsche Macan originates in the body manufacturing department everything begins with the fabrication of the underbody then comes the side sections as well as the time mostly with a large panoramic sunroof finally this is followed by attached parts such as the hood doors and tailgates all sheet metal parts for the car body come to Leipzig from different pressing plants here so-called route trains bring the raw components to the assembly stations the tractor trucks shine blue cones ahead of them to warn other vehicles against collisions because it's always rush hour in the production hall all assembly lines must be supplied just in time when the component is required the aluminum hoods wait a mere 17 kilograms they require special handling before later being installed in the car body it's unprecedented in automobile engineering that we put so much work here to a single component nearly a half hour per hood due to the complexity of the component and its component geometry you can see that it's physically very demanding requires lots of dexterity and vast experience deburring grinding sanding and polishing anything that does not fit here down to the millimeter may later delay installation and slow down production the processed hoods are taken over by the robot and automatically brought to the assembly station at the same time on the next line here robots assembled the underbody made of steel parts a perfectly synchronized spectacle with a precision of a clockwork and perpetual motion the robots sometimes perform two or three jobs in a row swapping tools providing for complete component handling gluing applications and welding an example of why there are only machines and no people working here a pair of welding tongues alone weighs roughly two hundred and eighty kilograms so it could not even be held by one person not to mention the fact that the same welding points have to be placed in exactly the same spot throughout the day the human colleagues support the machines in the body shop in regular intervals they have to beat the robots with screws so that they can complete their precision work car body assembly begins with the inner and outer sidewalls a robot provides the blank and the second one applies the special adhesive [Music] then the robot inserts the sidewalls onto the car body only now will it undergo the final welding the so-called framer ensures the precise geometry of the car body the subframe of the four point 86 meter long and 1.93 wide makann is now permanently fastened into place and the iconic silhouette begins to take shape incidentally it is based on the Audi q5 the mid-sized SUV of the company within the corporate group the robots spot-weld up to 5,300 welding points per makan body that is over 470 million welding points per year and each individual point has to be exactly in the right place no tolerance for variances then come the roof's buyers have a choice of eight different route variants in total and customisation place an even bigger role when it comes to other features later on in the end of photo scanner examines the exact workmanship and once again checks all the connection points the body shell of the Porsche Macan it now consists of the underbody and platform the only thing missing now are the various attached parts the car bodies advance on to the final assembly line via a sophisticated conveyor belt system each makan covers a distance of more than five kilometers on the assembly line before it even has wheels and while the vehicle is still traveling at a walking pace through the Assembly Hall out on the road a finished Porsche Macan can travel at speeds of up to 270 km/h Christina link is responsible for the installation of attached parts per production line runs in three shifts six days a week here the doors are custom fitted onto the vehicle and automatically bolted down afterwards the complete bolting specifications on the vehicle are stored for eternity so that we have a document of how precisely this door was bolted onto the vehicle those are the last steps the automated steps in car body manufacturing the preassembled steel doors of the Porsche Macan in an unfinished state they only wait 13 kilograms after final assembly fitted with interior components cladding and upholstery they become twice as heavy since the opening of the Leipzig factory Porsche has invested over 1.3 billion euros in this facility and it is always constantly expanding thanks to the successful makan model the sale value of Alma con produced here several billion euros the assembly lines are not allowed to come to a standstill under any circumstances which makes it all the more important to have reliable robots that work as maintenance-free as possible and what's more feature low power consumption Thomas reading ahead of planning has programmed the 400 strong robot army for economy thanks to an intelligent controller we are capable of accelerating the robots only to a level that is absolutely necessary we save energy accordingly when accelerating and braking if you consider that there are more than 400 robots installed here and if we can save just roughly 10% on each one then that's a really good contribution energy is saved in the halls through efficient robotic use and produced on the rooftops from natural solar energy the photovoltaic system consists of more than 17,500 modules the collectors generate five thousand megawatt hours per year with that amount of power an electrically driven Porsche could travel some five million kilometres immediately behind the assembly halls and the company's own circular track there is an entirely different world here Porsche has created ecological compensation areas for the sealed ground space eanes base coat is responsible for the natural landscape now the gate is opening up to our miniature Jurassic Park as I like to refer to it also behind the gate is the beginning of a six kilometre long off-road track here porsche customers and test drivers can explore the limits of their SUVs so when you're out on this 132 hectare off-road track you always see lots of wild animals for example we have deer here we have fallow deer we have field bunnies partridges we have an incredible diversity of species here that we would like to preserve and care for in this project this is where 245 horsepower encounters the original horsepower 25 X more ponies and 75 or rocks graze on this managed ecosystem here on the off-road track in a special area our customers can experience the vehicle they pick up here at the same time we care for the natural habitat this open countryside it's our contribution to biodiversity and occasionally an ore rocks also lands in the Porsche cafeteria as a sustainable state but more on that later first we want to return to the car body assembly hall for the makan the last work steps still need to be completed there [Music] workers mount the tailgates and several smaller attached parts for these final stages they have replaced the ubiquitous robots yet they still work for the same precision on the skeleton of the most successful horse in the Porsche stable the completed makan carbody now weighs nearly one-half of a metric ton 480 kilograms of steel and aluminum just waiting to be custom painted and to make their way towards final assembly but first quality control each individual makan car body is checked with utmost precision shift supervisor Antonio colic on day is responsible for ensuring that all car bodies are immaculate yes we can compare this to a pit stop the vehicles drive here as if they were on a race track employees inspect the surfaces the gaps and prepare the vehicles properly so that we can hand them off in 150 seconds and send them to the painting facility here comes the countdown the specialists have two and a half minutes to correct small deviations using a hammer a sander and a screwdriver this individual quality control is unique in mass production and for Porsche an absolute necessity as we can see an employee carefully inspects at least 140 vehicles per shift by hand he checks for any possible damage or scratches to the surface if a makan does not pass this test it is taken out of the line and required to go back for reworking afterwards it is reintroduced onto the line and required to go through quality control again but that should not happen very often because the time to complete a makan is very tight in order to meet customer demands after successfully passing quality control the makan car-bodies advanced to the paint shop in the next hall but first it's time to make a quick stop in one or three cafeterias it is connected to the final assembly hall where most of the employees work on the assembly line and take a break starting from 11:30 a.m. the preparations for lunch are in full swing during lunch time and in the evening the 4,300 employees can choose among various meals the just-in-time principle applies here as well head chef Norbert it's month ensures that everything is served fresh hot and above all on time in addition to the daily menu at a special price there are three other main dishes to choose from along with various side dishes desserts and salads at 11:30 a.m. the time has come this is when the first huge rush on the cafeteria takes place because now the workers from the early shift have half an hour to eat [Music] the greatest challenge each day is we begin at zero we offer different entrees every day at 11:30 a.m. employees come from the assembly line wanting a hot meal we know that within roughly 8 to 10 minutes 150 employees will come in wanting well-cooked food they don't like it to be tough the French fries ought to be crisp so this just-in-time concept is very important to us the workers need to eat in a hurry some of them needs several minutes to get from their location on the assembly line to the cafeteria typical German efficiency the daily menu is available for 3 euros 90 including a side dish today meatloaf the most popular meals believe it or not are always hearty foods like hamburgers and french fries curry Wurst a hundred and eighty grams with french fries nice and hearty even a normal schnitzel breaded is a leading favorite or doner kebab so there - we always have a larger food percentage of 20 to 25 percent [Music] by 2:00 p.m. at the latest the rush subsides that is when all employees need to be back at their workstations on the assembly line or in the office in the car body hall for example where audits take place three times a day they entail very detailed quality controls an each shift one car body is removed from the production line and a specialist goes over it with a fine-tooth comb there is no time pressure involved here only a keen eye and an intuition for detail a special sense of touch is naturally the most important skill of all we auditors have that special instinctive feel in our hands which you need in order to filter out waviness and uneven surfaces once the auditor has completed his evaluation he presents the results to the colleagues from the various manufacturing departments if there are production related defects these need to be identified and eliminated in order to uphold the high quality standards otherwise the rear trunk flap is without any defects except for a small sanded area that I would write down as a remark the corner area a keen eye for the most minor details despite the high production volume true modern mega manufacturing the next production step awaits the completed car bodies they come into the paint shop on a total space of 60,000 square meters the new-born maked Mekons receive their final color and that is a complicated process the first step a special cleaning procedure for the bodyshells lab technician Simona Clemens is responsible for ensuring that the paint on the vehicles will later have an immaculate shine the body shells come to us from the body construction facility and are chemically pre treated in order to ensure optimal cleaning of the car bodies from grease dirt aluminum residues and prepared for the next steps we have special specifications from chemical manufacturers and these key parameters must be met by adjusting the dosage of chemicals using more or less the cleaning solution needs to be mixed perfectly if the dosage isn't precise the tiniest contaminants on the car bodies could later lead to ugly flaws in the all-important paintwork following chemical cleaning is a very special immersion bath in this tank the vehicle frame receives special corrosion protection in the immersion bath there is a special electro deposition coating and completely desalinated water with a temperature of 33 degrees Celsius between the tank walls in the car body an electric current of 380 volts is applied initiating an electrochemical process as a result the positively charged paint particles are automatically attracted to the negatively charged makan car body the result of the cathodic electro deposition an extremely uniform coating of cavities and metal surfaces [Music] after the electro deposition coating the car bodies dry at 175 degrees Celsius for 50 minutes then they are ready for the next step the sealing of the welds robots and splash guard covers apply sealant to the welds using separately calibrated nozzles in addition they seal the underbody in order to protect it against impact from stones the process engineer Nathalie Mata cow monitors this important process directly prior to final coating Porsche we work with low density PVC material it has the advantage that we can apply the same volume yet lower weight to the car body which is relevant especially in the sports car segment between six and eight kilograms of PVC are applied to a single car body in the process the seething joints need to have perfect coverage in order to prevent moisture from later penetrating the car body in order to check how our wealth will look on the finished vehicle we produce so-called splash guards in this process the robot applies a weld to a sheet metal part and we are able to compare the welds one to one can take a look at the surface the join to the base material and the weld width in this case it's looking very good thanks to two different nozzles the robots can treat both narrow seams and impregnate surface ares once the underbody protection is dry it is finally time to advance to the actual painting absolute cleanliness is the highest priority not a single speck of dust or a single particle of lint is allowed to come between the prime car body and the final coat of paint otherwise paint flaws may occur and in the worst case individual body parts would have to be repainted that is why every square centimeter is polished now robots are applying the so-called filler paintin it's color is geared to the final paint coating of the car white for light exterior colors anthracite for dark exterior colors and medium grey for the color hues in between the filler balances out any remaining uneven surfaces in the car body and has UV protective characteristics it also enhances the brilliance of the paint finish the filler needs to dry for 40 minutes then the makan is ready for its final color there are a total of 16 standard colors to choose from benedict Krug is a process engineer and checks the sophisticated painting procedures here you see the paths that the robot completes on the makan engine lit in terms of color you can see the brush parameters that are programmed in case of process fluctuations we can intervene here in order to modify paint quantities speeds or paths read makan by the way tend to be the exception the most popular colors are white black and anthracite for an extra charge every conceivable individual color tone can be blended upon customer request there are also regional differences and paint preferences here you see one of the most popular color tones on the Chinese market mahogany brown metallic and here on the high rotation atomizer the paint is atomized into the tiniest particles using this belt the bell spins at forty to sixty thousand rpm generating very fine paint particles and these paint particles are wonderfully distributed over the entire car by the paint and a Porsche Macan is applied in four layers in the end it is 0.13 millimeters thick that is almost as thick as a human hair no human being would be capable of applying the paint as evenly as a paint spraying robot the entire painting process requires some 15 hours per vehicle including drying intervals during a testing time because we run a just-in-time production the sequence in which we complete the paint process is a revelant we can paint in red followed by blue then immediately in black in between each car body that the atomizer nozzles are rinsed and the paint changer is located in the front section of the arm we use the paint changes to switch the new color to be sprayed the paint loss that we have is minimum minimizer [Music] then comes the next highlight the final surface inspection Carsten Lippman checks in the light tunnel to ensure that each paint coat is applied flawlessly to the makan car body with these LEDs and these mirrors structured light is projected onto the body this helps us to detect even the tiniest faults in the paint coating should there be any visible defects they go through ultra fine sanding and a polished to a high-gloss finish [Music] the specialists in the light tunnel have exactly three minutes to review the work in detail and ensure Portia's quality control standards are met this also includes initial remedial measures in case of the tiniest irregularities in the surface good ice are indispensable here [Music] it probably looks somewhat strange for us to be hammering around on a freshly painted car my colleague just discovered a small uneven surface in the roof and now he's going to be working on it with a hammer afterwards the surface will once again be 100% smooth and the vehicle will be ready for sale other manufacturers do not allow themselves this luxury of genuine craftsmanship for paint inspection but Porsche holds itself to different standards even when delivering more than 90 thousand vehicles per year after painting is complete it's time for final assembly final assembly takes place in the factory's third and largest hall on a total of sixty thousand square meters the painted car body is fitted out to a complete car via conveyor belts the painted car bodies advance into the final assembly hall here they receive the all-important customer interface the interior fittings and all conceivable extra features according to customer preferences this is where customer preference begins to determine the final product and whether their makan will ultimately cost 60,000 euros or more than 100,000 euros final assembly is monitored by both Leisha he is responsible for ensuring that each and every makan rolls off the assembly line just in time the technician has a work area that the vehicle passes through in two minutes we speak of a so-called tact time this means that our customer cycle two minutes is a function of the number of vehicles that we are scheduled to build in the work time available we work in two shifts and the shift change occurs while the line is moving at 3 p.m. the colleagues all change shifts which means that actually we are constantly in vehicle production mode this means 1300 assembly workers each have 2 minutes to complete their individual specialized tasks surprisingly the first step of final assembly involves disassembly the doors are removed again they are fitted out on a separate door assembly line by the time all individual parts and the windows are installed each door gains up to 20 kilograms of additional weight depending upon the features and materials of the interior trim an important side effect of separate door assembly this means the interior spaces in the still exposed car body are more readily accessible to their colleagues much still has to be done depending upon customer preference the workers still have to install up to 5,000 different individual parts for each individual step there is a special team each having only two minutes the workers move on an assembly line along with the car body once they have completed their work step they walk back and start the process over again on the next car one of the key installation components is the cable harness here all the electrical lines in the Porsche Macan are preassembled and bundled they have a total length of up to three kilometers in this area the cable harnesses are installed one of the 5000 parts that go into the vehicle during the assembly line cycle perhaps a conspicuous feature is that we have very few robots here this is due to the variety this can be more effectively achieved by employees the variety of the parts and the customization concept it requires special logistics because every Porsche Macan is unique and produced according to customer request only that is why only very broad plans can be made in advance as to which part is going to be needed and in which quantities a logistical challenge of the highest order all day long trucks arrive at the loading dock of the assembly hall bringing parts for the interior trim manufactured by suppliers according to Porsche specifications every few minutes another truck arrives the workers and the logistics center unload this makes even Tetris seem straightforward Crysta Friedman ensures that all the parts land in the right place at the right time we consciously do not refer to this as our warehouse because we don't have traditional warehousing of parts carried out over days or weeks instead this areas for making parts available to our colleagues on the assembly line as needed so that they can be installed accordingly on the data installation here in the logistics department we work with roughly 800 suppliers of suppliers every day with the path that we need in production and assembly here for example we have a bin containing covers delivered this morning over the next 24 to 48 hours we will be installing these components in the montage a ton in special offer Bowen an amazing logistical feat [Music] the latest breakthrough a fully automated high bay warehouse all developed by the in-house team here critical small parts can be kept in temporary storage and called up at any time Bastien Miller was involved in the development of this warehousing concept he knows the inner workings of the fully encapsulated high bay rack system like no other in our warehouse we have a chaotic storage system which means that the material is distributed among various places as a result we can still obtain material if there is a disturbance in one part of the plant thanks to the warehousing administration software we can swap out the material to various places manage chaos this model enables Porsche to make maximum use of the storage room by each robot knowing precisely where each part was stored thanks to chips and barcodes and sophisticated robotic software this is possible the third Khaliq in the logistics crew is nick makan he oversees the vast warehouse racks and the distribution of their contents to the correct final destination down in the assembly hall in order to save space we are running a system of dynamic order picking dynamic order picking makes only the components available in the commissioning zone that are actually required for the next four or five vehicles all other components are positioned above the storage rack using a rack retrieval device so that when the component is actually required it is moved to the lower zone and made available to the order picking technician in concrete terms this means orders come automatically from the assembly line to the order picking storage rack wherever a green lamp is lit an employee is required to remove a part and put it into his trolley as soon as all ordered parts are on the trolley for the trip it drives directly to the assembly line because we assemble each vehicle according to custom specifications we have a huge variety of components in our logistics department this seat belt alone has 150 versions that we handle here in order to allow the employee on the assembly line to concentrate exclusively on the good quality of the vehicles in logistics we use a system that enables us to fit out vehicle specific trolleys and send these directly to the worker in doing so we use the so called pick by light system the system ensures that the employee only uses the components that he actually needs of them at the other end of the hall a delivery of cockpits has just arrived they are largely preassembled and ready for installation Christa Friedman checks several times daily to ensure the proper delivery of the key parts Franzi the truck has just unloaded these cockpit modules 50 over 800 suppliers make just-in-time deliveries to us which means that these cockpit modules are configured vehicle-specific no two cockpits are alike there are different leathers different surface finishes these modules are delivered here approximately three to four hours prior to being installed the consequence if a supplier truck where the shipment of cockpits is stuck in traffic for more than four hours several makaan need to be set aside in the assembly line the final stage until installation is very brief however these assembly ready cockpits do not need to travel even 100 metres in the hall here we see the cockpit installation work step for this job we have a handling device a so-called manipulator it is necessary due to the weight of the cockpit it is pivoted into the vehicle marking off installation sites so that we can find the exact position the cockpits are vehicle specific which means that they conform to the exact preferences of the customer exactly how they ordered it finish features [Music] accordingly this affects the weight of a cockpit and weighs between 50 and 90 kilograms without the steering wheel [Music] incidentally among the most popular special features in the interior of the makan are leather seats and entertainment systems with extras like these the final price quickly increases to over 90,000 euros there is a special feature in the underbody final assembly each makan is turned 90 degrees along its longitudinal axis this enables workers to stand upright and work ergonomically when they are finished with their job the car automatically tilts back into its original position now the all-important tension still needs to be installed there is a 4-cylinder 245 horsepower engine or a six-cylinder 354 horsepower engine in the S version and as a turbo model the makaan even comes with 440 horsepower under the hood for most Porsche customers the engine is thought to be the vehicles most important feature it is produced in a plant belonging to the corporation in Hungary and along with a dual-clutch transmission delivered to light see a very special moment is reached when the engine and the transmission are joined to become one drive unit [Music] the most popular engine on the makann is the six-cylinder version because it's just got more feeling to it and because it offers enough power in reserve here we are in the engine pre assembly area this is where the transmission and the engine are mated and forming the heart of each Porsche - installation into the makan the engine transmission unit is fitted out in Leipzig the generator starter catalytic converter and particle filter are installed in the machine then comes the first high point of final assembly the so called engagement in the process the fitted engine transmission unit is placed onto the front axle of the future makan and bolted together by experienced mechanics at the same time beneath the hall ceiling the almost completely mounted car bodies float in from final assembly it won't be long now the marriage of the car body engine and chassis so here we are in the heart of the assembly line the quickest marriage Chapel in Germany this is where the vehicle the car body is married to the axles and the engine 30 marriages occur per hour which means that a vehicle is married every two minutes the actual act doesn't involve much celebration they have to make do with a few robots as best man and bridesmaid they move the drivetrain with precision accuracy beneath the car body which is then also lowered automatically [Music] afterwards several workers connect cables and lines and fasten the tail pipes into place that's how it looks mass production of a premium car perfected and automated down to the most intricate detail the logo and the legend ensure that the soul is seated on the final stretch the seats still need to be installed into the makan with the help of a handling device 89% of all customers order leather seats by the way shortly before the finale the wheels are delivered pre-mounted tires on rims [Applause] the rims measure up to 21 inches in diameter and nearly all models come in an extra-wide version now come the very last touches and symbolic finishing then the work is complete a brand-new Porsche Macan rolls off the assembly line a rather it hovers off the assembly line now all it has to do is pass the final inspection here our vehicles are standing on their own wheels for the first time essentially this is where we begin putting the vehicle through the acid tests the control devices are evaluated and fed with data the axle is configured and the vehicles put into operation slightly more than 24 hours have passed since the initial parts of the makan body were conjoined [Music] and then the new Porsche Macan is ready for its maiden trip it is one of more than 500 cars rolling off the assembly line in the Leipzig factory today sale price ninety seven thousand four hundred fifty five euros including all special features that customer wanted [Music] Porcia test driver mike their Becca will now steer the car onto the factory zone test track this is no time for an electrical system to fail for a screw to be loose or for any strange noises in the unmistakable growl of the Porsche engine all my senses are on high alert and I pay special attention to my ears in order to simply identify any strange background noises I also pay attention to vibrations the factory driver tests the Hill Climb Assist and the automatic brake for downhill driving [Music] in order to do this job you ought to have a technical understanding of the vehicles to analyze where possible disturbance factors could crop up and what the reason for them could be I've told musk under sane at Porsche each individual vehicle is test driven by a professional over 500 cars per day not many manufacturers go to such lengths my buddies are totally jealous of the fact that I have such a cool job and drive a Porsche every day but a test drive is only allowed to reach one point six kilometers on the odometer a makan is delivered by that at the latest everything is fine with this vehicle crafted from 5500 parts and less than two days from mechanical robots and perfect synchronicity to the experience touch of the human hand with utmost precision and absolute passion those who wish to do so can pick up their portion makan personally in Leipzig in the pit lane of the customer center the new cars await their owners this vehicle costs more than 120,000 euros and the next generation of successful SUVs will be completely electric [Music] you

Channel: undefined

Views: 891,026

Rating: 4.8337064 out of 5

Keywords: Free Documentary, Documentaries, Full documentary, documentary - topic, documentary (tv genre), 4k, documentary 4k, 4k documentary, uhd documentary, engineering, german engineering, engineering documentary, high tech documentary, mega manufacturing, heavy equipment, industrial machinery, porsche factory, porsche documentary, porsche manufacturing process, porsche manufacturing, porsche macan, porsche macan factory, extreme engineering, extreme engineering - topic

Id: F3FUH9fVC_M

Length: 48min 14sec (2894 seconds)

Published: Fri Jan 10 2020

Reddit Comments

[u/_Stewie_Griffin]

love watching these. always blows my mind