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[Music]
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the Porsche Macan a compact SUV
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combining off-road qualities and
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everyday versatility with the DNA of a
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sports car in this plant four thousand
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three hundred employees produce over
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90,000 makan vehicles per year
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every single vehicle absolutely
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individual and bespoke manufactured to
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order
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[Music]
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a masterpiece of logistics and
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engineering design
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it's mega manufacturing with ultimate
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passion and absolute precision
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[Music]
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the pushy makan the most successful
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horse and the stable of this legendary
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sports car manufacturer the makan is
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available starting at around sixty
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thousand euros was several extras
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however the price tag quickly grows to
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more than one hundred thousand in the
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turbo version the makan goes 440
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horsepower acceleration from 0 to 100
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km/h and only 4.5 seconds its top speed
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is around 270 km/h
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the makan is built near Leipzig in
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eastern Germany production is divided up
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into three halls on more than 145,000
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square meters in the body shop the paint
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shop and in final assembly but this is
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where it all begins in the body shop the
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birthplace of the Porsche Macan
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on more than 35,000 square meters robots
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and people turn pure sheet metal into
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sub frames around the clock
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the robots are in temporal l production
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lines they can change their tool heads
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within seconds inserting various screws
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or placing welding points adapting on
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the spot to the demands of the car and
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customer eight hours is all they need
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for the entire production of a fully
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galvanized aluminum steel car body
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production manager hemming steinborn
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is responsible for ensuring that
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everything runs smoothly here the major
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challenge perfectly aligning all the
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different elements engineering people
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and material ensuring there's a perfect
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balance between quality and unit
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quantities retaining their outstanding
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quality and delivering volume a
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balancing act for premium manufacturers
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like Porsche here we have four hundred
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robots all together every day they make
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four hundred car bodies out of four
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hundred individual parts the whole thing
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doesn't work without employees we have
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400 employees and working throughout a
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24 hour a day keep body manufacturing up
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and running the subframe of the Porsche
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Macan originates in the body
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manufacturing department everything
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begins with the fabrication of the
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underbody then comes the side sections
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as well as the time mostly with a large
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panoramic sunroof
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finally this is followed by attached
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parts such as the hood doors and
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tailgates all sheet metal parts for the
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car body come to Leipzig from different
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pressing plants here so-called route
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trains bring the raw components to the
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assembly stations the tractor trucks
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shine blue cones ahead of them to warn
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other vehicles against collisions
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because it's always rush hour in the
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production hall all assembly lines must
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be supplied just in time when the
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component is required
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the aluminum hoods wait a mere 17
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kilograms they require special handling
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before later being installed in the car
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body it's unprecedented in automobile
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engineering that we put so much work
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here to a single component nearly a half
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hour per hood due to the complexity of
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the component and its component geometry
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you can see that it's physically very
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demanding requires lots of dexterity and
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vast experience deburring grinding
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sanding and polishing anything that does
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not fit here down to the millimeter may
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later delay installation and slow down
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production the processed hoods are taken
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over by the robot and automatically
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brought to the assembly station
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at the same time on the next line here
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robots assembled the underbody made of
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steel parts a perfectly synchronized
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spectacle with a precision of a
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clockwork and perpetual motion
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the robots sometimes perform two or
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three jobs in a row swapping tools
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providing for complete component
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handling gluing applications and welding
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an example of why there are only
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machines and no people working here a
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pair of welding tongues alone weighs
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roughly two hundred and eighty kilograms
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so it could not even be held by one
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person not to mention the fact that the
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same welding points have to be placed in
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exactly the same spot throughout the day
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the human colleagues support the
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machines in the body shop in regular
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intervals they have to beat the robots
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with screws so that they can complete
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their precision work
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car body assembly begins with the inner
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and outer sidewalls
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a robot provides the blank and the
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second one applies the special adhesive
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[Music]
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then the robot inserts the sidewalls
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onto the car body
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only now will it undergo the final
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welding the so-called framer ensures the
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precise geometry of the car body
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the subframe of the four point 86 meter
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long and 1.93 wide makann is now
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permanently fastened into place and the
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iconic silhouette begins to take shape
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incidentally it is based on the Audi q5
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the mid-sized SUV of the company within
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the corporate group
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the robots spot-weld up to 5,300 welding
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points per makan body that is over 470
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million welding points per year and each
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individual point has to be exactly in
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the right place no tolerance for
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variances then come the roof's buyers
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have a choice of eight different route
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variants in total and customisation
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place an even bigger role when it comes
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to other features later on in the end of
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photo scanner examines the exact
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workmanship and once again checks all
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the connection points
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the body shell of the Porsche Macan it
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now consists of the underbody and
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platform the only thing missing now are
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the various attached parts the car
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bodies advance on to the final assembly
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line via a sophisticated conveyor belt
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system each makan covers a distance of
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more than five kilometers on the
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assembly line before it even has wheels
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and while the vehicle is still traveling
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at a walking pace through the Assembly
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Hall out on the road a finished Porsche
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Macan can travel at speeds of up to 270
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km/h Christina link is responsible for
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the installation of attached parts per
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production line runs in three shifts six
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days a week
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here the doors are custom fitted onto
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the vehicle and automatically bolted
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down afterwards the complete bolting
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specifications on the vehicle are stored
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for eternity so that we have a document
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of how precisely this door was bolted
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onto the vehicle those are the last
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steps the automated steps in car body
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manufacturing the preassembled steel
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doors of the Porsche Macan in an
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unfinished state they only wait 13
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kilograms after final assembly fitted
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with interior components cladding and
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upholstery they become twice as heavy
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since the opening of the Leipzig factory
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Porsche has invested over 1.3 billion
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euros in this facility and it is always
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constantly expanding thanks to the
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successful makan model the sale value of
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Alma con produced here several billion
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euros
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the assembly lines are not allowed to
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come to a standstill under any
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circumstances which makes it all the
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more important to have reliable robots
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that work as maintenance-free as
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possible and what's more feature low
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power consumption
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Thomas reading ahead of planning has
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programmed the 400 strong robot army for
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economy thanks to an intelligent
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controller we are capable of
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accelerating the robots only to a level
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that is absolutely necessary we save
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energy accordingly when accelerating and
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braking if you consider that there are
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more than 400 robots installed here and
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if we can save just roughly 10% on each
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one then that's a really good
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contribution energy is saved in the
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halls through efficient robotic use and
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produced on the rooftops from natural
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solar energy the photovoltaic system
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consists of more than 17,500 modules the
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collectors generate five thousand
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megawatt hours per year with that amount
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of power an electrically driven Porsche
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could travel some five million
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kilometres immediately behind the
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assembly halls and the company's own
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circular track there is an entirely
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different world here Porsche has created
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ecological compensation areas for the
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sealed ground space eanes base coat is
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responsible for the natural landscape
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now the gate is opening up to our
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miniature Jurassic Park as I like to
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refer to it
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also behind the gate is the beginning of
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a six kilometre long off-road track here
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porsche customers and test drivers can
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explore the limits of their SUVs so when
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you're out on this 132 hectare off-road
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track you always see lots of wild
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animals for example we have deer here we
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have fallow deer we have field bunnies
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partridges we have an incredible
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diversity of species here that we would
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like to preserve and care for in this
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project this is where 245 horsepower
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encounters the original horsepower 25 X
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more ponies and 75 or rocks graze on
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this managed ecosystem here on the
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off-road track in a special area our
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customers can experience the vehicle
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they pick up here at the same time we
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care for the natural habitat this open
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countryside
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it's our contribution to biodiversity
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and occasionally an ore rocks also lands
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in the Porsche cafeteria as a
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sustainable state but more on that later
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first we want to return to the car body
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assembly hall for the makan the last
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work steps still need to be completed
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there
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[Music]
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workers mount the tailgates and several
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smaller attached parts for these final
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stages they have replaced the ubiquitous
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robots yet they still work for the same
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precision on the skeleton of the most
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successful horse in the Porsche stable
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the completed makan carbody now weighs
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nearly one-half of a metric ton 480
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kilograms of steel and aluminum just
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waiting to be custom painted and to make
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their way towards final assembly but
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first quality control each individual
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makan car body is checked with utmost
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precision shift supervisor Antonio colic
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on day is responsible for ensuring that
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all car bodies are immaculate yes we can
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compare this to a pit stop the vehicles
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drive here as if they were on a race
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track employees inspect the surfaces the
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gaps and prepare the vehicles properly
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so that we can hand them off in 150
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seconds and send them to the painting
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facility here comes the countdown the
00:15:00
specialists have two and a half minutes
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to correct small deviations using a
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hammer a sander and a screwdriver
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this individual quality control is
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unique in mass production and for
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Porsche an absolute necessity as we can
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see an employee carefully inspects at
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least 140 vehicles per shift by hand he
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checks for any possible damage or
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scratches to the surface
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if a makan does not pass this test it is
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taken out of the line and required to go
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back for reworking afterwards it is
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reintroduced onto the line and required
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to go through quality control again but
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that should not happen very often
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because the time to complete a makan is
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very tight in order to meet customer
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demands
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after successfully passing quality
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control the makan car-bodies advanced to
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the paint shop in the next hall but
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first it's time to make a quick stop in
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one or three cafeterias it is connected
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to the final assembly hall where most of
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the employees work on the assembly line
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and take a break starting from 11:30
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a.m. the preparations for lunch are in
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full swing during lunch time and in the
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evening the 4,300 employees can choose
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among various meals the just-in-time
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principle applies here as well head chef
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Norbert it's month ensures that
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everything is served fresh hot and above
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all on time in addition to the daily
00:16:53
menu at a special price there are three
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other main dishes to choose from along
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with various side dishes desserts and
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salads at 11:30 a.m. the time has come
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this is when the first huge rush on the
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cafeteria takes place because now the
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workers from the early shift have half
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an hour to eat
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[Music]
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the greatest challenge each day is we
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begin at zero we offer different entrees
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every day at 11:30 a.m. employees come
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from the assembly line wanting a hot
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meal we know that within roughly 8 to 10
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minutes 150 employees will come in
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wanting well-cooked food they don't like
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it to be tough the French fries ought to
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be crisp
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so this just-in-time concept is very
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important to us the workers need to eat
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in a hurry
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some of them needs several minutes to
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get from their location on the assembly
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line to the cafeteria typical German
00:17:54
efficiency the daily menu is available
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for 3 euros 90 including a side dish
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today meatloaf the most popular meals
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believe it or not are always hearty
00:18:09
foods like hamburgers and french fries
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curry Wurst a hundred and eighty grams
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with french fries nice and hearty even a
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normal schnitzel breaded is a leading
00:18:18
favorite or doner kebab so there - we
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always have a larger food percentage of
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20 to 25 percent
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[Music]
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by 2:00 p.m. at the latest the rush
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subsides that is when all employees need
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to be back at their workstations on the
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assembly line or in the office in the
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car body hall for example where audits
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take place three times a day they entail
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very detailed quality controls an each
00:18:56
shift one car body is removed from the
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production line and a specialist goes
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over it with a fine-tooth comb there is
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no time pressure involved here only a
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keen eye and an intuition for detail a
00:19:12
special sense of touch is naturally the
00:19:15
most important skill of all we auditors
00:19:17
have that special instinctive feel in
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our hands which you need in order to
00:19:20
filter out waviness and uneven surfaces
00:19:23
once the auditor has completed his
00:19:26
evaluation he presents the results to
00:19:29
the colleagues from the various
00:19:31
manufacturing departments if there are
00:19:33
production related defects these need to
00:19:36
be identified and eliminated in order to
00:19:39
uphold the high quality standards
00:19:42
otherwise the rear trunk flap is without
00:19:45
any defects except for a small sanded
00:19:47
area that I would write down as a remark
00:19:49
the corner area a keen eye for the most
00:19:54
minor details
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despite the high production volume true
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modern mega manufacturing the next
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production step awaits the completed car
00:20:05
bodies they come into the paint shop on
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a total space of 60,000 square meters
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the new-born maked Mekons receive their
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final color and that is a complicated
00:20:17
process the first step a special
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cleaning procedure for the bodyshells
00:20:22
lab technician Simona Clemens is
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responsible for ensuring that the paint
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on the vehicles will later have an
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immaculate shine the body shells come to
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us from the body construction facility
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and are chemically pre treated in order
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to ensure optimal cleaning of the car
00:20:39
bodies from grease dirt aluminum
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residues and prepared for the next steps
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we have special specifications from
00:20:47
chemical manufacturers and these key
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parameters must be met by adjusting the
00:20:52
dosage of chemicals using more or less
00:20:56
the cleaning solution needs to be mixed
00:20:59
perfectly if the dosage isn't precise
00:21:02
the tiniest contaminants on the car
00:21:04
bodies could later lead to ugly flaws in
00:21:07
the all-important paintwork following
00:21:12
chemical cleaning is a very special
00:21:15
immersion bath in this tank the vehicle
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frame receives special corrosion
00:21:21
protection in the immersion bath there
00:21:24
is a special electro deposition coating
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and completely desalinated water with a
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temperature of 33 degrees Celsius
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between the tank walls in the car body
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an electric current of 380 volts is
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applied initiating an electrochemical
00:21:41
process as a result the positively
00:21:45
charged paint particles are
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automatically attracted to the
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negatively charged makan car body the
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result of the cathodic electro
00:21:55
deposition an extremely uniform coating
00:21:57
of cavities and metal surfaces
00:22:04
[Music]
00:22:05
after the electro deposition coating the
00:22:08
car bodies dry at 175 degrees Celsius
00:22:12
for 50 minutes then they are ready for
00:22:15
the next step the sealing of the welds
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robots and splash guard covers apply
00:22:23
sealant to the welds using separately
00:22:26
calibrated nozzles in addition they seal
00:22:29
the underbody in order to protect it
00:22:31
against impact from stones the process
00:22:36
engineer Nathalie Mata cow monitors this
00:22:39
important process directly prior to
00:22:42
final coating Porsche we work with low
00:22:47
density PVC material it has the
00:22:50
advantage that we can apply the same
00:22:51
volume yet lower weight to the car body
00:22:53
which is relevant especially in the
00:22:55
sports car segment between six and eight
00:22:57
kilograms of PVC are applied to a single
00:23:00
car body in the process the seething
00:23:05
joints need to have perfect coverage in
00:23:08
order to prevent moisture from later
00:23:10
penetrating the car body in order to
00:23:13
check how our wealth will look on the
00:23:14
finished vehicle we produce so-called
00:23:16
splash guards in this process the robot
00:23:19
applies a weld to a sheet metal part and
00:23:21
we are able to compare the welds one to
00:23:23
one can take a look at the surface the
00:23:25
join to the base material and the weld
00:23:27
width in this case it's looking very
00:23:29
good
00:23:32
thanks to two different nozzles the
00:23:35
robots can treat both narrow seams and
00:23:38
impregnate surface ares once the
00:23:41
underbody protection is dry it is
00:23:43
finally time to advance to the actual
00:23:46
painting
00:23:50
absolute cleanliness is the highest
00:23:53
priority not a single speck of dust or a
00:23:56
single particle of lint is allowed to
00:23:59
come between the prime car body and the
00:24:01
final coat of paint otherwise paint
00:24:05
flaws may occur and in the worst case
00:24:08
individual body parts would have to be
00:24:10
repainted that is why every square
00:24:13
centimeter is polished
00:24:17
now robots are applying the so-called
00:24:19
filler paintin it's color is geared to
00:24:22
the final paint coating of the car white
00:24:25
for light exterior colors anthracite for
00:24:28
dark exterior colors and medium grey for
00:24:32
the color hues in between
00:24:35
the filler balances out any remaining
00:24:37
uneven surfaces in the car body and has
00:24:41
UV protective characteristics it also
00:24:44
enhances the brilliance of the paint
00:24:46
finish the filler needs to dry for 40
00:24:49
minutes then the makan is ready for its
00:24:52
final color there are a total of 16
00:24:55
standard colors to choose from benedict
00:24:59
Krug is a process engineer and checks
00:25:02
the sophisticated painting procedures
00:25:05
here you see the paths that the robot
00:25:07
completes on the makan engine lit in
00:25:09
terms of color you can see the brush
00:25:11
parameters that are programmed in case
00:25:14
of process fluctuations we can intervene
00:25:16
here in order to modify paint quantities
00:25:19
speeds or paths read makan by the way
00:25:24
tend to be the exception the most
00:25:27
popular colors are white black and
00:25:29
anthracite for an extra charge every
00:25:34
conceivable individual color tone can be
00:25:37
blended upon customer request
00:25:45
there are also regional differences and
00:25:48
paint preferences
00:25:53
here you see one of the most popular
00:25:56
color tones on the Chinese market
00:25:57
mahogany brown metallic and here on the
00:26:01
high rotation atomizer the paint is
00:26:03
atomized into the tiniest particles
00:26:05
using this belt the bell spins at forty
00:26:08
to sixty thousand rpm generating very
00:26:10
fine paint particles and these paint
00:26:13
particles are wonderfully distributed
00:26:14
over the entire car by the paint and a
00:26:20
Porsche Macan is applied in four layers
00:26:23
in the end it is 0.13 millimeters thick
00:26:27
that is almost as thick as a human hair
00:26:30
no human being would be capable of
00:26:33
applying the paint as evenly as a paint
00:26:35
spraying robot the entire painting
00:26:38
process requires some 15 hours per
00:26:40
vehicle including drying intervals
00:26:44
during a testing time because we run a
00:26:47
just-in-time production the sequence in
00:26:50
which we complete the paint process is a
00:26:51
revelant we can paint in red followed by
00:26:55
blue then immediately in black in
00:26:57
between each car body that the atomizer
00:26:59
nozzles are rinsed and the paint changer
00:27:02
is located in the front section of the
00:27:03
arm we use the paint changes to switch
00:27:07
the new color to be sprayed the paint
00:27:09
loss that we have is minimum minimizer
00:27:15
[Music]
00:27:19
then comes the next highlight the final
00:27:22
surface inspection Carsten Lippman
00:27:25
checks in the light tunnel to ensure
00:27:26
that each paint coat is applied
00:27:28
flawlessly to the makan car body with
00:27:33
these LEDs and these mirrors structured
00:27:36
light is projected onto the body this
00:27:38
helps us to detect even the tiniest
00:27:41
faults in the paint coating should there
00:27:43
be any visible defects they go through
00:27:45
ultra fine sanding and a polished to a
00:27:48
high-gloss finish
00:27:49
[Music]
00:27:59
the specialists in the light tunnel have
00:28:01
exactly three minutes to review the work
00:28:03
in detail and ensure Portia's quality
00:28:06
control standards are met this also
00:28:09
includes initial remedial measures in
00:28:12
case of the tiniest irregularities in
00:28:15
the surface good ice are indispensable
00:28:17
here
00:28:22
[Music]
00:28:23
it probably looks somewhat strange for
00:28:26
us to be hammering around on a freshly
00:28:27
painted car my colleague just discovered
00:28:30
a small uneven surface in the roof and
00:28:32
now he's going to be working on it with
00:28:33
a hammer afterwards the surface will
00:28:36
once again be 100% smooth and the
00:28:38
vehicle will be ready for sale other
00:28:45
manufacturers do not allow themselves
00:28:48
this luxury of genuine craftsmanship for
00:28:51
paint inspection but Porsche holds
00:28:53
itself to different standards even when
00:28:56
delivering more than 90 thousand
00:28:58
vehicles per year after painting is
00:29:01
complete it's time for final assembly
00:29:03
final assembly takes place in the
00:29:05
factory's third and largest hall on a
00:29:08
total of sixty thousand square meters
00:29:10
the painted car body is fitted out to a
00:29:13
complete car via conveyor belts the
00:29:17
painted car bodies advance into the
00:29:19
final assembly hall
00:29:22
here they receive the all-important
00:29:25
customer interface the interior fittings
00:29:28
and all conceivable extra features
00:29:30
according to customer preferences this
00:29:34
is where customer preference begins to
00:29:36
determine the final product and whether
00:29:38
their makan will ultimately cost 60,000
00:29:41
euros or more than 100,000 euros final
00:29:46
assembly is monitored by both Leisha he
00:29:49
is responsible for ensuring that each
00:29:51
and every makan rolls off the assembly
00:29:53
line just in time the technician has a
00:29:57
work area that the vehicle passes
00:29:59
through in two minutes we speak of a
00:30:01
so-called tact time this means that our
00:30:03
customer cycle two minutes is a function
00:30:05
of the number of vehicles that we are
00:30:07
scheduled to build in the work time
00:30:08
available we work in two shifts and the
00:30:11
shift change occurs while the line is
00:30:12
moving at 3 p.m. the colleagues all
00:30:15
change shifts which means that actually
00:30:17
we are constantly in vehicle production
00:30:19
mode this means 1300 assembly workers
00:30:27
each have 2 minutes to complete their
00:30:29
individual specialized tasks
00:30:33
surprisingly the first step of final
00:30:35
assembly involves disassembly the doors
00:30:38
are removed again
00:30:43
they are fitted out on a separate door
00:30:46
assembly line
00:30:49
by the time all individual parts and the
00:30:52
windows are installed each door gains up
00:30:55
to 20 kilograms of additional weight
00:30:57
depending upon the features and
00:30:59
materials of the interior trim an
00:31:03
important side effect of separate door
00:31:05
assembly
00:31:07
this means the interior spaces in the
00:31:10
still exposed car body are more readily
00:31:13
accessible to their colleagues
00:31:19
much still has to be done depending upon
00:31:22
customer preference the workers still
00:31:24
have to install up to 5,000 different
00:31:27
individual parts for each individual
00:31:30
step there is a special team each having
00:31:33
only two minutes
00:31:38
the workers move on an assembly line
00:31:40
along with the car body once they have
00:31:43
completed their work step they walk back
00:31:45
and start the process over again on the
00:31:48
next car one of the key installation
00:31:52
components is the cable harness here all
00:31:55
the electrical lines in the Porsche
00:31:56
Macan are preassembled and bundled they
00:32:00
have a total length of up to three
00:32:01
kilometers
00:32:06
in this area the cable harnesses are
00:32:09
installed one of the 5000 parts that go
00:32:12
into the vehicle during the assembly
00:32:13
line cycle
00:32:14
perhaps a conspicuous feature is that we
00:32:17
have very few robots here this is due to
00:32:20
the variety this can be more effectively
00:32:23
achieved by employees the variety of the
00:32:29
parts and the customization concept it
00:32:32
requires special logistics because every
00:32:39
Porsche Macan is unique and produced
00:32:42
according to customer request only that
00:32:46
is why only very broad plans can be made
00:32:49
in advance as to which part is going to
00:32:51
be needed and in which quantities a
00:32:54
logistical challenge of the highest
00:32:56
order
00:32:57
all day long trucks arrive at the
00:33:00
loading dock of the assembly hall
00:33:01
bringing parts for the interior trim
00:33:04
manufactured by suppliers
00:33:05
according to Porsche specifications
00:33:08
every few minutes another truck arrives
00:33:11
the workers and the logistics center
00:33:13
unload this makes even Tetris seem
00:33:17
straightforward
00:33:18
Crysta Friedman ensures that all the
00:33:21
parts land in the right place at the
00:33:23
right time we consciously do not refer
00:33:27
to this as our warehouse because we
00:33:29
don't have traditional warehousing of
00:33:31
parts carried out over days or weeks
00:33:33
instead this areas for making parts
00:33:36
available to our colleagues on the
00:33:37
assembly line as needed so that they can
00:33:40
be installed accordingly on the data
00:33:41
installation here in the logistics
00:33:45
department we work with roughly 800
00:33:48
suppliers of suppliers every day with
00:33:49
the path that we need in production and
00:33:51
assembly here for example we have a bin
00:33:54
containing covers delivered this morning
00:33:56
over the next 24 to 48 hours we will be
00:34:00
installing these components in the
00:34:02
montage a ton in special offer Bowen an
00:34:06
amazing logistical feat
00:34:10
[Music]
00:34:16
the latest breakthrough a fully
00:34:19
automated high bay warehouse all
00:34:21
developed by the in-house team here
00:34:24
critical small parts can be kept in
00:34:26
temporary storage and called up at any
00:34:29
time
00:34:30
Bastien Miller was involved in the
00:34:32
development of this warehousing concept
00:34:34
he knows the inner workings of the fully
00:34:37
encapsulated high bay rack system like
00:34:40
no other in our warehouse we have a
00:34:43
chaotic storage system which means that
00:34:45
the material is distributed among
00:34:47
various places as a result we can still
00:34:49
obtain material if there is a
00:34:50
disturbance in one part of the plant
00:34:52
thanks to the warehousing administration
00:34:54
software we can swap out the material to
00:34:57
various places manage chaos this model
00:35:03
enables Porsche to make maximum use of
00:35:05
the storage room by each robot knowing
00:35:08
precisely where each part was stored
00:35:11
thanks to chips and barcodes and
00:35:13
sophisticated robotic software this is
00:35:17
possible
00:35:22
the third Khaliq in the logistics crew
00:35:24
is nick makan he oversees the vast
00:35:27
warehouse racks and the distribution of
00:35:31
their contents to the correct final
00:35:32
destination down in the assembly hall
00:35:38
in order to save space we are running a
00:35:41
system of dynamic order picking dynamic
00:35:44
order picking makes only the components
00:35:47
available in the commissioning zone that
00:35:49
are actually required for the next four
00:35:50
or five vehicles all other components
00:35:53
are positioned above the storage rack
00:35:55
using a rack retrieval device so that
00:35:57
when the component is actually required
00:35:59
it is moved to the lower zone and made
00:36:01
available to the order picking
00:36:02
technician in concrete terms this means
00:36:11
orders come automatically from the
00:36:13
assembly line to the order picking
00:36:15
storage rack wherever a green lamp is
00:36:19
lit an employee is required to remove a
00:36:22
part and put it into his trolley as soon
00:36:25
as all ordered parts are on the trolley
00:36:27
for the trip it drives directly to the
00:36:30
assembly line because we assemble each
00:36:35
vehicle according to custom
00:36:37
specifications we have a huge variety of
00:36:39
components in our logistics department
00:36:41
this seat belt alone has 150 versions
00:36:45
that we handle here in order to allow
00:36:47
the employee on the assembly line to
00:36:49
concentrate exclusively on the good
00:36:51
quality of the vehicles in logistics we
00:36:54
use a system that enables us to fit out
00:36:56
vehicle specific trolleys and send these
00:36:58
directly to the worker in doing so we
00:37:01
use the so called pick by light system
00:37:03
the system ensures that the employee
00:37:06
only uses the components that he
00:37:08
actually needs of them
00:37:13
at the other end of the hall
00:37:16
a delivery of cockpits has just arrived
00:37:19
they are largely preassembled and ready
00:37:21
for installation Christa Friedman checks
00:37:26
several times daily to ensure the proper
00:37:29
delivery of the key parts
00:37:33
Franzi the truck has just unloaded these
00:37:36
cockpit modules 50 over 800 suppliers
00:37:40
make just-in-time deliveries to us which
00:37:42
means that these cockpit modules are
00:37:44
configured vehicle-specific no two
00:37:47
cockpits are alike there are different
00:37:49
leathers different surface finishes
00:37:51
these modules are delivered here
00:37:53
approximately three to four hours prior
00:37:54
to being installed the consequence if a
00:38:03
supplier truck where the shipment of
00:38:04
cockpits is stuck in traffic for more
00:38:07
than four hours several makaan need to
00:38:10
be set aside in the assembly line the
00:38:14
final stage until installation is very
00:38:16
brief however these assembly ready
00:38:19
cockpits do not need to travel even 100
00:38:22
metres in the hall here we see the
00:38:25
cockpit installation work step for this
00:38:28
job we have a handling device a
00:38:29
so-called manipulator it is necessary
00:38:32
due to the weight of the cockpit it is
00:38:34
pivoted into the vehicle marking off
00:38:36
installation sites so that we can find
00:38:38
the exact position the cockpits are
00:38:40
vehicle specific which means that they
00:38:42
conform to the exact preferences of the
00:38:44
customer exactly how they ordered it
00:38:46
finish features
00:38:49
[Music]
00:38:51
accordingly this affects the weight of a
00:38:54
cockpit and weighs between 50 and 90
00:38:57
kilograms without the steering wheel
00:38:59
[Music]
00:39:02
incidentally among the most popular
00:39:04
special features in the interior of the
00:39:07
makan are leather seats and
00:39:09
entertainment systems with extras like
00:39:13
these the final price quickly increases
00:39:16
to over 90,000 euros
00:39:25
there is a special feature in the
00:39:28
underbody final assembly
00:39:30
each makan is turned 90 degrees along
00:39:33
its longitudinal axis this enables
00:39:37
workers to stand upright and work
00:39:39
ergonomically when they are finished
00:39:42
with their job the car automatically
00:39:44
tilts back into its original position
00:39:46
now the all-important tension still
00:39:49
needs to be installed there is a
00:39:52
4-cylinder 245 horsepower engine or a
00:39:57
six-cylinder 354 horsepower engine in
00:40:00
the S version and as a turbo model the
00:40:04
makaan even comes with 440 horsepower
00:40:06
under the hood for most Porsche
00:40:13
customers the engine is thought to be
00:40:15
the vehicles most important feature
00:40:19
it is produced in a plant belonging to
00:40:21
the corporation in Hungary and along
00:40:24
with a dual-clutch transmission
00:40:25
delivered to light see
00:40:31
a very special moment is reached when
00:40:34
the engine and the transmission are
00:40:36
joined to become one drive unit
00:40:39
[Music]
00:40:43
the most popular engine on the makann is
00:40:46
the six-cylinder version because it's
00:40:48
just got more feeling to it and because
00:40:49
it offers enough power in reserve here
00:40:52
we are in the engine pre assembly area
00:40:54
this is where the transmission and the
00:40:55
engine are mated and forming the heart
00:40:57
of each Porsche - installation into the
00:41:09
makan the engine transmission unit is
00:41:11
fitted out in Leipzig the generator
00:41:15
starter catalytic converter and particle
00:41:18
filter are installed in the machine then
00:41:22
comes the first high point of final
00:41:24
assembly the so called engagement
00:41:29
in the process the fitted engine
00:41:31
transmission unit is placed onto the
00:41:33
front axle of the future makan and
00:41:36
bolted together by experienced mechanics
00:41:45
at the same time beneath the hall
00:41:48
ceiling the almost completely mounted
00:41:50
car bodies float in from final assembly
00:41:56
it won't be long now the marriage of the
00:42:00
car body engine and chassis so here we
00:42:06
are in the heart of the assembly line
00:42:07
the quickest marriage Chapel in Germany
00:42:10
this is where the vehicle the car body
00:42:12
is married to the axles and the engine
00:42:14
30 marriages occur per hour which means
00:42:16
that a vehicle is married every two
00:42:18
minutes
00:42:24
the actual act doesn't involve much
00:42:27
celebration they have to make do with a
00:42:29
few robots as best man and bridesmaid
00:42:35
they move the drivetrain with precision
00:42:37
accuracy beneath the car body which is
00:42:40
then also lowered automatically
00:42:46
[Music]
00:42:48
afterwards several workers connect
00:42:51
cables and lines and fasten the tail
00:42:53
pipes into place that's how it looks
00:42:57
mass production of a premium car
00:43:00
perfected and automated down to the most
00:43:03
intricate detail the logo and the legend
00:43:08
ensure that the soul is seated
00:43:13
on the final stretch the seats still
00:43:16
need to be installed into the makan with
00:43:19
the help of a handling device 89% of all
00:43:23
customers order leather seats by the way
00:43:34
shortly before the finale the wheels are
00:43:38
delivered pre-mounted tires on rims
00:43:44
[Applause]
00:43:47
the rims measure up to 21 inches in
00:43:50
diameter and nearly all models come in
00:43:53
an extra-wide version
00:43:56
now come the very last touches and
00:43:59
symbolic finishing
00:44:06
then the work is complete a brand-new
00:44:10
Porsche Macan rolls off the assembly
00:44:12
line a rather it hovers off the assembly
00:44:15
line
00:44:21
now all it has to do is pass the final
00:44:25
inspection here our vehicles are
00:44:28
standing on their own wheels for the
00:44:30
first time essentially this is where we
00:44:32
begin putting the vehicle through the
00:44:33
acid tests the control devices are
00:44:35
evaluated and fed with data the axle is
00:44:38
configured and the vehicles put into
00:44:39
operation slightly more than 24 hours
00:44:48
have passed since the initial parts of
00:44:51
the makan body were conjoined
00:44:58
[Music]
00:45:00
and then the new Porsche Macan is ready
00:45:05
for its maiden trip it is one of more
00:45:09
than 500 cars rolling off the assembly
00:45:11
line in the Leipzig factory today sale
00:45:15
price ninety seven thousand four hundred
00:45:18
fifty five euros including all special
00:45:21
features that customer wanted
00:45:23
[Music]
00:45:31
Porcia test driver mike their Becca will
00:45:34
now steer the car onto the factory zone
00:45:36
test track this is no time for an
00:45:42
electrical system to fail for a screw to
00:45:45
be loose or for any strange noises in
00:45:47
the unmistakable growl of the Porsche
00:45:50
engine all my senses are on high alert
00:45:54
and I pay special attention to my ears
00:45:56
in order to simply identify any strange
00:45:59
background noises I also pay attention
00:46:01
to vibrations the factory driver tests
00:46:06
the Hill Climb Assist
00:46:08
and the automatic brake for downhill
00:46:12
driving
00:46:14
[Music]
00:46:17
in order to do this job you ought to
00:46:20
have a technical understanding of the
00:46:21
vehicles to analyze where possible
00:46:23
disturbance factors could crop up and
00:46:26
what the reason for them could be
00:46:27
I've told musk under sane at Porsche
00:46:32
each individual vehicle is test driven
00:46:34
by a professional over 500 cars per day
00:46:38
not many manufacturers go to such
00:46:41
lengths my buddies are totally jealous
00:46:46
of the fact that I have such a cool job
00:46:48
and drive a Porsche every day but a test
00:46:55
drive is only allowed to reach one point
00:46:57
six kilometers on the odometer a makan
00:47:01
is delivered by that at the latest
00:47:06
everything is fine with this vehicle
00:47:12
crafted from 5500 parts and less than
00:47:16
two days from mechanical robots and
00:47:19
perfect synchronicity to the experience
00:47:23
touch of the human hand with utmost
00:47:25
precision and absolute passion
00:47:35
those who wish to do so can pick up
00:47:38
their portion makan personally in
00:47:40
Leipzig in the pit lane of the customer
00:47:43
center the new cars await their owners
00:47:47
this vehicle costs more than 120,000
00:47:51
euros and the next generation of
00:47:55
successful SUVs will be completely
00:47:58
electric
00:48:03
[Music]
00:48:05
you
