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Narrator: A german car company
is making its mark in america.
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Mysteries of the italian master
coffee makers are revealed.
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♪♪
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A multipurpose
construction workhorse
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Has truly made
a name for itself.
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And razor-sharp technology
is being used
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To produce the world's
most futuristic guitar.
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These groundbreaking innovations
are all taking place
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Inside some of the most
incredible factories
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On the planet.
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♪♪
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-- Captions by vitac --
www.Vitac.Com
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Captions paid for by
discovery communications
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Narrator: Situated along
the tennessee river
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Between nashville and atlanta,
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This city is home
to 180,000 people,
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And now one of the most
modern factories in the world --
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Volkswagen.
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The german-based car giant
began production here in 2011.
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♪♪
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Chattanooga is volkswagen's
only plant in the united states,
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And it's their newest plant
in the group.
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Narrator: Built at a cost
of roughly a billion dollars,
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The factory campus covers
60 million square feet.
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The buildings alone make up
almost 25,000 square feet,
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Enough space for over
2 million people.
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But there are actually fewer
than 4,000 people working here.
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That's because they're joined
by close to a thousand machines
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Like these, at the cutting edge
of robot technology.
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[ whirring ]
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♪♪
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They've been programmed
to lift heavy components,
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To operate a welding lance
with remarkable precision,
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And to spray more evenly
than any human operator could.
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These intelligent robots turn
out 750 automobiles every day.
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♪♪
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That's four cars
every five minutes.
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♪♪
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This super factory is
the latest and greatest
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In cutting-edge
vehicle production.
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But that's not all.
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It's officially classified
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As the u.S.A.'s greenest
automobile factory.
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Since volkswagen
was founded in 1937,
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They've been responsible
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For some of the most
recognizable
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Automobiles in the world.
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Today, here at chattanooga,
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They're producing
one brand new model
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And an update on an old
favorite, the passat sedan,
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A name familiar for four decades
now in its eighth generation.
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And a newcomer, the atlas
s.U.V., launched in 2017.
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The process of turning raw steel
into a finished automobile
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Is similar for both models.
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It all begins
in the body shop.
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Body shop is the first step
in the production process.
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We receive pre-stamped parts
from our suppliers,
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And then these parts
are distributed throughout
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The body shop
by our logistics team.
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The body of the car,
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The raw metal pieces, are pieced
together like a puzzle.
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So 80 percent of the work
in the body shop is automated.
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♪♪
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What robots do best are tasks
that are absolutely repetitive
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With little or no variation,
and that stands to reason
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Because they're responding
to the program
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That the human operator
has inputted it into the.
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♪♪
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Narrator: In the body shop,
robots weld together
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The vehicles' steel shell.
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♪♪
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They use what are called
diode disk lasers,
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Seven times
more energy efficient
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Than conventional
laser welding machines,
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Saving 220,000 kilowatt hours
of electricity a year.
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But the laser robots
emit so much light
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That they have to operate
in a sealed environment.
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Their progress is monitored
via a video feed.
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Once all of these processes
are done
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And the raw metal
is pieced together,
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It's lifted up into
an overhead conveyor
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And shifted into the paint shop.
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Narrator: The painting stage
is a five-step process.
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For the base coat,
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The car body is totally
immersed in a paint bath.
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♪♪
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After successive layers
have been built up,
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Robots carefully apply
the final topcoat.
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And then the entire shell
is baked in a giant oven.
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It takes a lot of power,
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But volkswagen has adopted
a green solution.
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This super factory harvests
its own electricity
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From the sun.
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Banks of solar panels,
33,600 in all,
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Annually generate 13.1 million
kilowatt hours of energy.
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That's enough to power
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Nearly 1,200 u.S. Homes
for a whole year.
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And it's 12.5 percent of this
factory's yearly power usage.
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♪♪
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The land this factory is built
on has a remarkable history.
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This site was formerly
an explosive factory
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Operating from world war ii
to the vietnam war.
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Well, when volkswagen
first moved to chattanooga,
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We looked for areas
that were brownfields,
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Which means that they were
previously industrial sites.
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Narrator: The evidence of its
former role is still here
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In the surrounding woods
containing abandoned bunkers
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That used to store bombs,
bullets, shells, and grenades.
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Today, this site
is very different.
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Volkswagen's
green initiatives here
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Have earned it
the top platinum award
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From an international body
called leadership in energy
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And environmental design,
or leed for short.
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When we decided to build
energy efficient,
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We said, "let's go
to the top of leed."
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We were the first automotive
facility that's leed platinum.
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Narrator: Some of these
new green practices
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Are put to use
down on the shop floor,
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Where the workers are moving
forward with making cars.
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All the elements
which need to be fitted
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Inside the painted
vehicle shell
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Are pieced together on
five separate subassembly lines.
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Specialist teams are responsible
for the engine and the chassis.
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The point at which
they're united with the body
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Is known as the marriage.
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Other teams look after
the installation
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Of the instrument panel...
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♪♪
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The wheels...
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♪♪
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...And then the trim,
which defines the brand.
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What's remarkable
about the assembly line
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Is how few robots they have here
compared to the body shop.
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My assembly shop
is very human oriented.
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We have less than a handful
of robots, so almost no robots
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In this assembly shop.
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Out of the whole shop,
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We have less than
a handful of robots
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Really only applying
some of the adhesives.
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So we really depend
on our team members
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For the quality of the product.
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Stirling:
In assembly lines,
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Some of the jobs are just
far too nuanced and varied
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For a robot
to be truly effective.
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Tasks that require
decision making,
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Creativity,
and on-the-job learning
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Are really still
best done by humans.
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♪♪
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Narrator: And that's
definitely the case
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On the final stage here
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In the chattanooga
super auto plant,
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Where each finished vehicle's
suspension is put to the test
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On what must be one of america's
most uncomfortable roads.
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♪♪
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The test driver goes through
a rigorous checklist
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To make sure everything inside
the vehicle is up to scratch.
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Every one of the 750 vehicles
produced here each day
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Undergoes this top-to-bottom
check before being shipped out.
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♪♪
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Chattanooga's famous
for its railroads,
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And that's how these automobiles
make their first ever journey.
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[ chattering ]
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In an efficient
and environmentally friendly
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Move by volkswagen,
80 percent of the factory output
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Is dispatched by train
instead of truck.
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But the biggest advancement
in sustainable technology
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Is just around the corner.
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Volkswagen, more so, arguably,
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Than a lot of the other
big names,
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Has staked its future
on electric cars.
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They say the cost of batteries,
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Previously the big
limiting factor,
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Has come down 80 percent
in the last 10 years.
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They say that over
the next decade
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They'll be releasing
70 electric models.
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Narrator: Vw has named
chattanooga as the site
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To make its first
electric vehicles in the u.S.
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Models like these, including
a new take on the legendary bus
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Or camper van, ready
to hit the road in 2022.
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It's a massive vote
of confidence
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In this super auto plant
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Now on the verge
of becoming even greener,
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Bigger, and smarter,
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Making this one of the world's
major centers
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For producing
the vehicles of the future.
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♪♪
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Coming up,
mysteries of the italian
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Master coffee makers
are revealed.
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00:10:27,928 --> 00:10:30,762
And later,
a construction vehicle
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Built tough enough to handle
whatever crosses its path.
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This machine has been called
the swiss army knife
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Of the building site.
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♪♪
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♪♪
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[ beeping ]
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♪♪
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Narrator:
Italians love coffee,
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00:11:02,929 --> 00:11:05,897
But nowhere more so
than trieste,
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Where they consume
over 22 pounds a year,
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00:11:09,136 --> 00:11:12,137
Twice the national average.
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00:11:12,139 --> 00:11:14,739
And here in Italy's
coffee capital,
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There's one brand
that stands out above the rest.
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Illy has grown from one
small cafe opened in 1933
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To this extensive
high-tech super factory.
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00:11:29,823 --> 00:11:32,190
From here,
the company exports coffee
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00:11:32,192 --> 00:11:34,659
To 140 countries,
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00:11:34,661 --> 00:11:39,130
With seven million cups served
every day across the world.
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♪♪
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Illy prides itself
on tradition.
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Three generations of the family
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00:11:46,573 --> 00:11:49,607
Have produced the same
coffee blend for decades.
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00:11:51,078 --> 00:11:52,677
But there's nothing
old-fashioned
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00:11:52,679 --> 00:11:54,312
About this business.
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00:11:54,314 --> 00:11:57,716
Illy invented the forerunner
of the modern espresso machine,
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00:11:57,718 --> 00:12:00,318
The aletta, in the 1930s.
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00:12:00,320 --> 00:12:03,988
Ever since, the company has been
driven by innovation
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00:12:03,990 --> 00:12:06,324
Through the whole
coffee-making process.
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00:12:06,326 --> 00:12:11,596
♪♪
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00:12:11,598 --> 00:12:15,233
The story starts at the port.
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Every week,
ships arrive in trieste
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00:12:17,771 --> 00:12:20,038
From three different continents.
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00:12:20,040 --> 00:12:27,212
♪♪
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00:12:36,690 --> 00:12:38,556
Narrator: The beans are
from 20 countries,
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00:12:38,558 --> 00:12:42,794
Including brazil,
ethiopia, and india.
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00:12:42,796 --> 00:12:45,830
These well-traveled beans
are first washed free
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00:12:45,832 --> 00:12:48,199
Of dirt and dust,
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00:12:48,201 --> 00:12:50,935
Then sucked up massive pipes
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00:12:50,937 --> 00:12:54,706
And pneumatically whisked over
to the sorting plant.
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00:12:54,708 --> 00:12:57,942
Raw beans used to be
checked by eye,
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00:12:57,944 --> 00:13:01,379
But now they get a much more
high-tech inspection,
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00:13:01,381 --> 00:13:04,983
Thanks to another illy
engineering innovation.
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00:13:04,985 --> 00:13:07,051
The bichromatic processor
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00:13:07,053 --> 00:13:10,789
Can check 11,000 beans
a second.
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00:13:10,791 --> 00:13:14,759
The machine analyzes the color
of every single bean
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00:13:14,761 --> 00:13:18,696
By running them past red,
green, and infrared filters.
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00:13:31,278 --> 00:13:34,379
It may seem like overkill
to analyze every single bean
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00:13:34,381 --> 00:13:36,581
In a 45-ton batch,
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00:13:36,583 --> 00:13:39,217
But actually sorting out the bad
from the good is important.
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00:13:39,219 --> 00:13:41,753
It was a job
that used to be done by eye,
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00:13:41,755 --> 00:13:44,489
But it is crucial
because it takes only one bean
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00:13:44,491 --> 00:13:48,726
In a portion of 50 to spoil
the flavor of your brew.
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00:13:48,728 --> 00:13:50,328
♪♪
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00:13:50,330 --> 00:13:56,668
But making a premium coffee
is not just about sorting beans.
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00:13:56,670 --> 00:13:59,671
Here in the illy
blending and tasting lab,
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00:13:59,673 --> 00:14:01,840
They keep it relatively simple.
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00:14:01,842 --> 00:14:05,777
They make just
one blend of coffee.
247
00:14:05,779 --> 00:14:08,780
And given seasonal variations
in global production
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00:14:08,782 --> 00:14:10,348
And availability,
249
00:14:10,350 --> 00:14:13,751
They're constantly striving
to get the right mix of beans
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00:14:13,753 --> 00:14:15,753
For their traditional blend.
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00:14:17,824 --> 00:14:21,059
There are over 100 species
of coffee,
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00:14:21,061 --> 00:14:22,760
But really only two
253
00:14:22,762 --> 00:14:26,631
Are commercially grown --
arabica and robusta.
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00:14:26,633 --> 00:14:28,333
There are
significant differences
255
00:14:28,335 --> 00:14:31,803
Between these in terms
of cost and flavor.
256
00:14:31,805 --> 00:14:35,139
Robusta has much more caffeine
than arabica,
257
00:14:35,141 --> 00:14:37,008
Which you might think
would be an advantage,
258
00:14:37,010 --> 00:14:40,778
But actually, caffeine has
a really bitter taste.
259
00:14:40,780 --> 00:14:44,782
Well, arabica has more lipids,
and these create a sweet,
260
00:14:44,784 --> 00:14:46,384
Mellow flavor.
261
00:14:46,386 --> 00:14:49,320
But robusta is much easier
to farm.
262
00:14:49,322 --> 00:14:52,690
It's got higher yields,
and therefore is much cheaper.
263
00:14:52,692 --> 00:14:56,027
In fact, half the cost
of arabica.
264
00:14:56,029 --> 00:14:59,631
Narrator: Robusta is the main
constituent in instant coffee,
265
00:14:59,633 --> 00:15:03,301
But it's rarely found
in a quality blend.
266
00:15:03,303 --> 00:15:05,336
Illy's top-secret formula
267
00:15:05,338 --> 00:15:10,308
Is a combination
of nine types of arabica beans.
268
00:15:10,310 --> 00:15:12,644
The batches of beans are mixed
and blended
269
00:15:12,646 --> 00:15:16,180
In a highly restricted
part of the plant.
270
00:15:16,182 --> 00:15:20,084
Then they arrive here,
the roasting room.
271
00:15:29,062 --> 00:15:32,263
Narrator: Now the illy roasters
employ their alchemy
272
00:15:32,265 --> 00:15:36,034
To turn the raw beans
into coffee gold.
273
00:15:36,036 --> 00:15:39,837
To succeed, they must take
300 aromatic compounds
274
00:15:39,839 --> 00:15:41,572
Contained in the raw beans
275
00:15:41,574 --> 00:15:43,775
And more than triple
that number.
276
00:15:43,777 --> 00:15:45,777
They do that by roasting.
277
00:15:59,459 --> 00:16:04,462
Narrator: The beans are roasted
at 392 degrees fahrenheit.
278
00:16:04,464 --> 00:16:07,999
The raw coffee bean really has
a very limited flavor profile.
279
00:16:08,001 --> 00:16:10,501
It's often described
as green or musty.
280
00:16:10,503 --> 00:16:11,869
But in that raw bean,
281
00:16:11,871 --> 00:16:13,805
There's what you need
to create flavor later.
282
00:16:13,807 --> 00:16:17,141
There's sugars, carbohydrates,
nitrogen compounds.
283
00:16:17,143 --> 00:16:19,344
But it's not until the bean
is roasted
284
00:16:19,346 --> 00:16:22,347
That the potential of the flavor
of the coffee is unlocked.
285
00:16:22,349 --> 00:16:24,949
You actually create
very volatile compounds
286
00:16:24,951 --> 00:16:27,552
Which give aroma
and the flavor profile
287
00:16:27,554 --> 00:16:28,987
That is coffee.
288
00:16:28,989 --> 00:16:30,989
Basically,
coffee only tastes like coffee
289
00:16:30,991 --> 00:16:33,658
Once the bean is roasted.
290
00:16:33,660 --> 00:16:35,126
Narrator:
But roasting coffee
291
00:16:35,128 --> 00:16:37,962
Is a highly
time-sensitive process.
292
00:16:37,964 --> 00:16:42,734
And to uphold their reputation,
illy has to get it just right.
293
00:16:48,008 --> 00:16:50,375
♪♪
294
00:16:51,945 --> 00:16:54,312
♪♪
295
00:16:55,448 --> 00:17:00,651
♪♪
296
00:17:00,653 --> 00:17:03,321
Narrator: Trieste is
the coffee capital of Italy,
297
00:17:03,323 --> 00:17:07,759
And home to the family-owned
gourmet coffee company illy,
298
00:17:07,761 --> 00:17:10,995
Who has been producing
the same premium coffee blend
299
00:17:10,997 --> 00:17:12,730
For decades.
300
00:17:12,732 --> 00:17:14,966
At illy's super factory,
301
00:17:14,968 --> 00:17:19,337
Raw beans are being roasted
into coffee gold.
302
00:17:19,339 --> 00:17:23,408
The control room team monitors
the roast second by second.
303
00:17:32,385 --> 00:17:34,652
Narrator:
After 15 minutes,
304
00:17:34,654 --> 00:17:37,522
The control room shuts down
the process.
305
00:17:37,524 --> 00:17:40,391
While correct roasting
creates new compounds,
306
00:17:40,393 --> 00:17:42,760
Over-roasting destroys them.
307
00:17:42,762 --> 00:17:46,364
So now it's crucial
to stop the cooking.
308
00:17:46,366 --> 00:17:48,366
To keep the aromas intact,
309
00:17:48,368 --> 00:17:51,736
The beans are blasted
with cold air.
310
00:17:51,738 --> 00:17:55,573
Now they need to get the coffee
packed quickly,
311
00:17:55,575 --> 00:17:57,875
Because once exposed to air,
312
00:17:57,877 --> 00:18:02,313
The aromatic compounds
will start to dissipate.
313
00:18:02,315 --> 00:18:06,117
The roasted coffee
is divided into two batches,
314
00:18:06,119 --> 00:18:09,120
Some left as whole beans.
315
00:18:09,122 --> 00:18:11,456
The rest is ground.
316
00:18:11,458 --> 00:18:13,124
Coffee lasts longer
317
00:18:13,126 --> 00:18:15,426
If it's stored
in an airtight container,
318
00:18:15,428 --> 00:18:19,097
Which keeps out oxygen
and moisture.
319
00:18:19,099 --> 00:18:22,834
Unlike most coffee producers
who use vacuum-packed bags,
320
00:18:22,836 --> 00:18:24,969
Illy uses tins.
321
00:18:24,971 --> 00:18:27,171
Not only are
the tins recyclable,
322
00:18:27,173 --> 00:18:29,874
They're a great
marketing device.
323
00:18:29,876 --> 00:18:32,143
This brand-conscious company
324
00:18:32,145 --> 00:18:35,913
Even sells limited edition
artist-designed tins.
325
00:18:38,585 --> 00:18:40,551
Back on the factory floor,
326
00:18:40,553 --> 00:18:43,621
The tins are on their way
to the coffee.
327
00:18:55,101 --> 00:18:59,137
Narrator: The camera checks that
the tin isn't damaged or dirty.
328
00:18:59,139 --> 00:19:02,206
Once in the tins,
the freshly roasted coffee
329
00:19:02,208 --> 00:19:05,276
Is shaken --
automatically, of course.
330
00:19:20,226 --> 00:19:22,293
Narrator:
The coffee is in the can,
331
00:19:22,295 --> 00:19:26,264
But now it's time for one of
illy's most clever innovations.
332
00:19:26,266 --> 00:19:28,799
They call it
natural pressurization.
333
00:19:47,520 --> 00:19:51,789
Narrator: Unlike oxygen,
nitrogen is an inert gas,
334
00:19:51,791 --> 00:19:54,692
Which means it doesn't react
with the coffee,
335
00:19:54,694 --> 00:19:58,963
Killing the aromas
and therefore the flavor.
336
00:19:58,965 --> 00:20:02,400
Pressurization effectively
traps the essential aromas
337
00:20:02,402 --> 00:20:04,101
Inside the tin,
338
00:20:04,103 --> 00:20:07,838
Protecting the coffee
from oxidization and humidity.
339
00:20:09,375 --> 00:20:12,109
When I open a tin of coffee
like this,
340
00:20:12,111 --> 00:20:16,147
You get that really distinctive
whooshing sound.
341
00:20:16,149 --> 00:20:17,715
[ pops ]
342
00:20:17,717 --> 00:20:20,785
That was the sound of the
nitrogen rushing out.
343
00:20:20,787 --> 00:20:22,486
And then...
344
00:20:22,488 --> 00:20:23,921
[ sniffs ]
345
00:20:23,923 --> 00:20:25,656
Oh, that amazing smell
346
00:20:25,658 --> 00:20:28,326
Of thousands
of coffee aromas.
347
00:20:28,328 --> 00:20:30,494
It really is worth
getting up for.
348
00:20:30,496 --> 00:20:32,163
[ sniffs ]
349
00:20:32,165 --> 00:20:36,234
Sadly, those aromas are even
now starting to fade.
350
00:20:36,236 --> 00:20:40,137
Roasted coffee loses up
to 40 percent of its aroma
351
00:20:40,139 --> 00:20:41,772
Over an eight-hour period.
352
00:20:41,774 --> 00:20:46,043
♪♪
353
00:20:46,045 --> 00:20:49,180
Narrator: Pressurized packaging
was a major breakthrough.
354
00:20:49,182 --> 00:20:51,916
It enabled illy to keep
the aroma of the coffee
355
00:20:51,918 --> 00:20:54,118
Constant at all times.
356
00:20:54,120 --> 00:20:57,855
This innovation made it possible
to export coffee
357
00:20:57,857 --> 00:21:02,026
All around the globe
from one site here in trieste.
358
00:21:03,529 --> 00:21:06,130
Pressurized packaging
was a major breakthrough.
359
00:21:06,132 --> 00:21:07,732
It enabled illy
360
00:21:07,734 --> 00:21:13,137
To keep the aroma of the coffee
constant at all times.
361
00:21:13,139 --> 00:21:15,673
But illy was the first major
coffee company
362
00:21:15,675 --> 00:21:20,878
To manufacture espresso pods,
way back in 1974.
363
00:21:20,880 --> 00:21:28,219
♪♪
364
00:21:28,221 --> 00:21:30,588
Whether ground or whole beans,
365
00:21:30,590 --> 00:21:33,491
In tins or espresso cups,
366
00:21:33,493 --> 00:21:34,759
It all ends up here
367
00:21:34,761 --> 00:21:37,895
In the futuristic
illy packaging plant.
368
00:21:42,068 --> 00:21:44,535
Here in trieste,
people have been drinking
369
00:21:44,537 --> 00:21:48,105
Illy coffee since 1933.
370
00:21:48,107 --> 00:21:50,941
And now,
in their super factory,
371
00:21:50,943 --> 00:21:53,778
Illy is using science,
innovation,
372
00:21:53,780 --> 00:21:55,546
And the latest technology
373
00:21:55,548 --> 00:21:59,617
To revolutionize how they
manufacture their unique blend
374
00:21:59,619 --> 00:22:02,887
And ensure that their coffee
is enjoyed
375
00:22:02,889 --> 00:22:06,324
By millions
all around the world.
376
00:22:06,326 --> 00:22:08,726
Coming up,
the secrets behind
377
00:22:08,728 --> 00:22:11,929
A construction
jack of all trades.
378
00:22:11,931 --> 00:22:14,365
Woman: This machine can dig,
it can lift, it can load,
379
00:22:14,367 --> 00:22:17,234
It can shovel,
it can excavate.
380
00:22:17,236 --> 00:22:20,338
Narrator: And later,
in japan's guitar valley,
381
00:22:20,340 --> 00:22:23,708
This highly distinctive guitar
is putting the cut
382
00:22:23,710 --> 00:22:25,276
In. Cutting edge.
383
00:22:25,278 --> 00:22:28,546
Man: It is a challenge
for most guitar factories
384
00:22:28,548 --> 00:22:30,848
Because it requires
a lot of precision
385
00:22:30,850 --> 00:22:33,951
To actually obtain
the features that we want.
386
00:22:33,953 --> 00:22:35,686
♪♪
387
00:22:37,557 --> 00:22:40,291
♪♪
388
00:22:42,295 --> 00:22:45,896
[ beeping ]
389
00:22:45,898 --> 00:22:49,467
♪♪
390
00:22:49,469 --> 00:22:52,570
Narrator: This super factory
in rochester, England,
391
00:22:52,572 --> 00:22:55,172
Is the birthplace
of the go-to workhorse
392
00:22:55,174 --> 00:22:59,176
For civil engineering,
construction, and agriculture
393
00:22:59,178 --> 00:23:02,947
That's literally helped build
the world we live in --
394
00:23:02,949 --> 00:23:04,882
The backhoe loader,
395
00:23:04,884 --> 00:23:06,617
Known in the u.K.
396
00:23:06,619 --> 00:23:09,387
And listed in the oxford
english dictionary
397
00:23:09,389 --> 00:23:12,156
As simply a jcb.
398
00:23:12,158 --> 00:23:14,458
This machine has been called
the swiss army knife
399
00:23:14,460 --> 00:23:16,494
Of the building site --
it can dig,
400
00:23:16,496 --> 00:23:18,596
It can lift,
it can load, it can shovel,
401
00:23:18,598 --> 00:23:21,432
It can excavate,
and it can speed between jobs
402
00:23:21,434 --> 00:23:24,368
At a steady
40 kilometers an hour.
403
00:23:24,370 --> 00:23:26,604
Narrator: This revolutionary
piece of equipment
404
00:23:26,606 --> 00:23:29,173
Was invented
by a maverick engineer
405
00:23:29,175 --> 00:23:31,509
Working alone in his garage.
406
00:23:31,511 --> 00:23:35,012
Gough: Jcb stands for
joseph cyril bamford,
407
00:23:35,014 --> 00:23:36,781
The man behind the legend.
408
00:23:36,783 --> 00:23:41,619
His first attempt at producing
a mechanical excavator in 1948
409
00:23:41,621 --> 00:23:44,321
Was rather do-it-yourself,
410
00:23:44,323 --> 00:23:47,458
He persisted,
and five years later,
411
00:23:47,460 --> 00:23:51,529
He came up with the world's
first backhoe loader.
412
00:23:51,531 --> 00:23:55,299
Today, jcb is a
multi-billion-dollar company
413
00:23:55,301 --> 00:23:59,336
With over 12,000 employees
all round the world.
414
00:23:59,338 --> 00:24:01,071
♪♪
415
00:24:01,073 --> 00:24:04,942
Narrator: Jcb manufactures
vehicles around the globe,
416
00:24:04,944 --> 00:24:08,479
But this is what they call
their world headquarters.
417
00:24:08,481 --> 00:24:11,782
Here, 90 of the iconic
backhoe loaders
418
00:24:11,784 --> 00:24:15,119
Roll off the line
every 24 hours.
419
00:24:15,121 --> 00:24:18,255
♪♪
420
00:24:18,257 --> 00:24:22,560
It takes five days
to build a backhoe loader.
421
00:24:22,562 --> 00:24:25,496
And this no-nonsense
heavy working vehicle
422
00:24:25,498 --> 00:24:30,301
Starts with
a solid block of steel.
423
00:24:30,303 --> 00:24:32,336
Carder: The chassis
is the main structure
424
00:24:32,338 --> 00:24:33,838
Which holds
the machine together.
425
00:24:33,840 --> 00:24:36,574
So all the forces and the
stresses when you're digging
426
00:24:36,576 --> 00:24:38,375
Actually go back
through the chassis.
427
00:24:38,377 --> 00:24:41,178
So it needs to be very, very
tough and strong, durable.
428
00:24:42,515 --> 00:24:44,849
Narrator: Cutting up steel
used to be dirty,
429
00:24:44,851 --> 00:24:47,952
Dangerous, and time consuming.
430
00:24:47,954 --> 00:24:51,088
But here, they use lasers.
431
00:24:51,090 --> 00:24:55,993
♪♪
432
00:24:55,995 --> 00:24:58,429
Guided by a computer blueprint,
433
00:24:58,431 --> 00:25:01,265
The infrared beam slices
through hard metal
434
00:25:01,267 --> 00:25:02,967
Like a knife through butter.
435
00:25:05,304 --> 00:25:09,240
With high-speed precision,
this intense beam of light
436
00:25:09,242 --> 00:25:12,009
Cuts out the complex series
of metal shapes
437
00:25:12,011 --> 00:25:13,944
Needed to assemble the chassis.
438
00:25:13,946 --> 00:25:17,248
♪♪
439
00:25:17,250 --> 00:25:21,352
A laser is monochromatic light,
usually blue or red,
440
00:25:21,354 --> 00:25:24,221
Or it could be infrared
or ultraviolet.
441
00:25:24,223 --> 00:25:27,258
This monochromatic light
shoots a much narrower beam
442
00:25:27,260 --> 00:25:28,993
Over a much longer distance
443
00:25:28,995 --> 00:25:31,896
And is much more precise
and powerful.
444
00:25:31,898 --> 00:25:35,099
Laser cutting used to be
the stuff of james bond movies.
445
00:25:35,101 --> 00:25:37,201
No longer is that the case.
Now you'll find them
446
00:25:37,203 --> 00:25:40,838
In industry, in universities,
even in schools.
447
00:25:40,840 --> 00:25:43,240
Narrator:
This once solid sheet of steel
448
00:25:43,242 --> 00:25:45,342
Is now sliced and diced,
449
00:25:45,344 --> 00:25:48,579
Crisscrossed with outlines
of chassis components.
450
00:25:48,581 --> 00:25:51,515
And not only is
the laser highly accurate,
451
00:25:51,517 --> 00:25:52,950
It hates waste.
452
00:25:52,952 --> 00:25:54,685
Carder:
So after the laser cutting,
453
00:25:54,687 --> 00:25:57,154
This is what's left over,
which is now a scrap.
454
00:25:57,156 --> 00:26:01,292
So we have around about 90
percent material optimization
455
00:26:01,294 --> 00:26:03,327
And say minimal wastage.
456
00:26:03,329 --> 00:26:05,095
Narrator:
The scraps are recycled,
457
00:26:05,097 --> 00:26:08,933
But what's left makes up
the pieces of the digger jigsaw.
458
00:26:08,935 --> 00:26:11,201
Before the pieces
can be put together,
459
00:26:11,203 --> 00:26:14,038
They need to be
pressed into shape.
460
00:26:14,040 --> 00:26:16,874
This machine can
press up to 20 millimeters,
461
00:26:16,876 --> 00:26:19,443
With about 230 ton of force.
462
00:26:19,445 --> 00:26:21,612
So when the parts are being cut
to shape,
463
00:26:21,614 --> 00:26:23,113
They then get
put into the presses
464
00:26:23,115 --> 00:26:25,883
To be shaped into
three-dimensional pieces.
465
00:26:25,885 --> 00:26:29,887
Narrator:
The steel has been lasered,
shaped, and pressed.
466
00:26:29,889 --> 00:26:33,090
Now it will be welded to form
the chassis.
467
00:26:33,092 --> 00:26:35,392
Welding essentially melts
two metals together,
468
00:26:35,394 --> 00:26:36,827
And where they touch,
469
00:26:36,829 --> 00:26:39,830
When that metal solidifies,
it binds them together.
470
00:26:39,832 --> 00:26:41,599
And there are many ways
of achieving this,
471
00:26:41,601 --> 00:26:44,201
Including the most popular ways
of arc welding
472
00:26:44,203 --> 00:26:45,703
And gas flame welding.
473
00:26:45,705 --> 00:26:47,204
And today there are numerous
474
00:26:47,206 --> 00:26:51,141
Sophisticated ways of welding
in very extreme environments,
475
00:26:51,143 --> 00:26:54,678
Including underwater
and even in outer space.
476
00:26:54,680 --> 00:26:57,414
Narrator: Down on earth,
at this plant,
477
00:26:57,416 --> 00:27:01,018
It's not just humans
wielding the welding torches.
478
00:27:01,020 --> 00:27:04,388
Manual welding is carried out
in tight spots.
479
00:27:04,390 --> 00:27:08,592
Everywhere else,
it's done by robots.
480
00:27:08,594 --> 00:27:12,596
This robotic welder fires out
a 5,000-degree fahrenheit
481
00:27:12,598 --> 00:27:15,633
Burst of oxygen
and acetylene gas,
482
00:27:15,635 --> 00:27:19,670
Connecting up two sheets of
metal in split seconds.
483
00:27:19,672 --> 00:27:22,506
Once the chassis is all
in one piece,
484
00:27:22,508 --> 00:27:25,042
It needs to be smoothed clean.
485
00:27:25,044 --> 00:27:28,178
To do that, it's bombarded
at high velocity
486
00:27:28,180 --> 00:27:31,882
With thousands
of tiny steel pellets.
487
00:27:31,884 --> 00:27:34,818
This process,
called shot blasting,
488
00:27:34,820 --> 00:27:38,055
Is carried out
in an isolated chamber.
489
00:27:38,057 --> 00:27:40,024
So this is the
completed chassis,
490
00:27:40,026 --> 00:27:42,292
Which has now been through
the shot blasting machine
491
00:27:42,294 --> 00:27:43,794
For about ten minutes.
492
00:27:43,796 --> 00:27:46,196
That's all in preparation
for painting.
493
00:27:49,235 --> 00:27:53,871
Narrator: The chassis is sprayed
with primer and gloss.
494
00:27:53,873 --> 00:27:59,543
And here at jcb,
there's only one color option.
495
00:27:59,545 --> 00:28:01,745
So the standard color
we paint all our machines
496
00:28:01,747 --> 00:28:03,447
Is a jcb yellow,
497
00:28:03,449 --> 00:28:05,683
Which is actually
our own unique color
498
00:28:05,685 --> 00:28:07,351
That you can't find
anywhere else.
499
00:28:07,353 --> 00:28:08,952
♪♪
500
00:28:08,954 --> 00:28:13,691
Narrator:
Backhoes were originally
painted orange and blue,
501
00:28:13,693 --> 00:28:16,126
But were later painted
bright yellow
502
00:28:16,128 --> 00:28:20,330
To make them more visible
on busy construction sites.
503
00:28:20,332 --> 00:28:24,435
This, the very latest
in a long line of loaders,
504
00:28:24,437 --> 00:28:27,504
Is ready to take its place
on the assembly line.
505
00:28:27,506 --> 00:28:29,540
Here, it will join
the procession
506
00:28:29,542 --> 00:28:31,208
Of partially built machines
507
00:28:31,210 --> 00:28:34,311
Steadily moving down
the floor level conveyer.
508
00:28:34,313 --> 00:28:37,014
The jcb plant works
around the clock.
509
00:28:37,016 --> 00:28:41,418
Shifts may change, but loaders
keep moving down the line.
510
00:28:41,420 --> 00:28:43,654
It's time to bring in
some power.
511
00:28:43,656 --> 00:28:48,025
The dieselmax 672, produced
20 miles down the road
512
00:28:48,027 --> 00:28:50,728
At jcb's engine plant.
513
00:28:50,730 --> 00:28:54,932
This six-cylinder, 7.2-liter
turbocharged engine
514
00:28:54,934 --> 00:28:57,901
Has been updated to give
increased fuel efficiency
515
00:28:57,903 --> 00:29:00,003
And produce lower emissions.
516
00:29:00,005 --> 00:29:03,640
With the engine and gearbox
attached to the rear axle,
517
00:29:03,642 --> 00:29:08,178
The chassis is swung over
and neatly dropped into place.
518
00:29:08,180 --> 00:29:11,315
But not all the power
comes from the engine.
519
00:29:11,317 --> 00:29:14,518
The front shovel and rear
excavating backhoe are driven
520
00:29:14,520 --> 00:29:17,321
By an extremely
strong source of energy.
521
00:29:17,323 --> 00:29:20,457
It's pumped through a series
of hoses and pistons
522
00:29:20,459 --> 00:29:23,627
And known as the hydraulics.
523
00:29:23,629 --> 00:29:27,631
Hydraulic power systems
are simple but extremely strong.
524
00:29:27,633 --> 00:29:30,134
All sorts of things use
hydraulics --
525
00:29:30,136 --> 00:29:34,638
Trains, aircraft controls,
braking systems, and of course,
526
00:29:34,640 --> 00:29:37,040
The business end
of diggers.
527
00:29:37,042 --> 00:29:39,510
Hydraulics work
by applying a force at one point
528
00:29:39,512 --> 00:29:42,913
And moving that force
to another point using liquids.
529
00:29:42,915 --> 00:29:46,650
The hydraulic fluid is pushed
through hoses at high pressure,
530
00:29:46,652 --> 00:29:48,452
And it can deliver
a huge amount of power
531
00:29:48,454 --> 00:29:53,257
For driving machinery --
like the attachments on a jcb.
532
00:29:53,259 --> 00:29:58,328
Narrator: This vehicle is almost
all in one piece.
533
00:29:58,330 --> 00:30:00,931
Now it's time for the cab.
534
00:30:02,468 --> 00:30:05,536
With ergonomic controls,
soundproofing,
535
00:30:05,538 --> 00:30:08,138
Touch screens,
and air conditioning,
536
00:30:08,140 --> 00:30:10,674
This model is certainly
an upgrade
537
00:30:10,676 --> 00:30:13,710
From the 1953 original.
538
00:30:13,712 --> 00:30:15,846
With the brakes and wheels
fitted,
539
00:30:15,848 --> 00:30:18,215
This brand-new model
is just about ready
540
00:30:18,217 --> 00:30:22,352
To get down and dirty
and roll in the mud.
541
00:30:22,354 --> 00:30:25,222
But first, this
fresh-off-the-line model
542
00:30:25,224 --> 00:30:27,825
Faces a series
of performance tests
543
00:30:27,827 --> 00:30:29,860
And rigorous inspection.
544
00:30:29,862 --> 00:30:31,161
Carder: Every single machine
goes through
545
00:30:31,163 --> 00:30:33,463
A very, very extensive
hot test.
546
00:30:33,465 --> 00:30:35,899
Do about checks
on every single machine.
547
00:30:35,901 --> 00:30:38,035
♪♪
548
00:30:38,037 --> 00:30:41,839
Narrator: From plates of steel
to one of the hardest working,
549
00:30:41,841 --> 00:30:46,743
Easily recognizable, and most
iconic machines in the world,
550
00:30:46,745 --> 00:30:50,347
All put together
in less than five days
551
00:30:50,349 --> 00:30:52,249
Here in one of
the most advanced
552
00:30:52,251 --> 00:30:54,918
Engineering plants
in the world,
553
00:30:54,920 --> 00:30:58,088
The jcb super factory.
554
00:30:58,090 --> 00:31:01,225
♪♪
555
00:31:01,227 --> 00:31:04,828
Coming up, a factory
in japan's guitar valley
556
00:31:04,830 --> 00:31:07,664
Is producing
a highly distinctive sound.
557
00:31:07,666 --> 00:31:09,166
♪♪
558
00:31:09,168 --> 00:31:12,636
Man: It's really hard to make
this kind of instrument
559
00:31:12,638 --> 00:31:16,306
Because the neck back shape
560
00:31:16,308 --> 00:31:20,277
Is particularly,
you know, really unique.
561
00:31:20,279 --> 00:31:24,581
♪♪
562
00:31:26,452 --> 00:31:28,819
♪♪
563
00:31:31,757 --> 00:31:35,559
[ beeping ]
564
00:31:35,561 --> 00:31:37,594
♪♪
565
00:31:37,596 --> 00:31:39,830
Narrator: Three hours' drive
west of tokyo
566
00:31:39,832 --> 00:31:43,066
Is matsumoto, japan.
567
00:31:43,068 --> 00:31:46,436
The city was once famous
for its carpentry workshops,
568
00:31:46,438 --> 00:31:52,042
But since the 1960s, it's been
known as japan's guitar valley.
569
00:31:52,044 --> 00:31:55,178
Squeezed in among the factories
of guitar giants
570
00:31:55,180 --> 00:31:57,047
Such as fender and gretsch
571
00:31:57,049 --> 00:32:00,617
Is one much more
bespoke operation,
572
00:32:00,619 --> 00:32:04,087
Producing a highly
distinctive instrument.
573
00:32:04,089 --> 00:32:07,791
This is a strandberg.
574
00:32:07,793 --> 00:32:11,261
With its headless neck
and ergonomic body,
575
00:32:11,263 --> 00:32:14,097
A strandberg simply doesn't
look like other
576
00:32:14,099 --> 00:32:15,999
Electric guitars look,
577
00:32:16,001 --> 00:32:19,970
And it isn't made the way
many other guitars are made.
578
00:32:19,972 --> 00:32:24,274
It's put together using the
very latest digital technology.
579
00:32:24,276 --> 00:32:27,878
This instrument breaks
the basic electric guitar mold,
580
00:32:27,880 --> 00:32:30,580
Set as far back as the 1930s,
581
00:32:30,582 --> 00:32:33,850
And is nothing short of
a revolution in guitar
582
00:32:33,852 --> 00:32:36,687
Design and manufacturing.
583
00:32:36,689 --> 00:32:40,557
Strandberg may not be one of
the world's biggest factories,
584
00:32:40,559 --> 00:32:43,160
But it's definitely
one of the smartest.
585
00:32:43,162 --> 00:32:49,433
♪♪
586
00:32:49,435 --> 00:32:51,234
Like all guitar makers,
587
00:32:51,236 --> 00:32:54,871
The strandberg team starts off
with a basic block of wood.
588
00:32:54,873 --> 00:32:58,342
But unlike many manufacturers
who use hardwoods
589
00:32:58,344 --> 00:33:00,377
Such as maple or mahogany,
590
00:33:00,379 --> 00:33:02,779
This team uses softwoods
591
00:33:02,781 --> 00:33:05,849
Such as american basswood
and swamp ash.
592
00:33:05,851 --> 00:33:09,987
They're valued for resonance,
what guitar aficionados call
593
00:33:09,989 --> 00:33:12,289
A warm, sweet sound.
594
00:33:12,291 --> 00:33:14,157
But it's when it comes
to cutting the wood
595
00:33:14,159 --> 00:33:15,792
To make the guitar body
596
00:33:15,794 --> 00:33:18,261
Things start to get
really different.
597
00:33:18,263 --> 00:33:19,997
Instead of skilled craftsmen
598
00:33:19,999 --> 00:33:21,832
Cutting out
intricate shapes,
599
00:33:21,834 --> 00:33:25,936
Here, an operator simply taps
some computer keys.
600
00:33:25,938 --> 00:33:28,238
Now the guitar's
design blueprint
601
00:33:28,240 --> 00:33:31,475
Is digitally relayed
to the cutting tools.
602
00:33:31,477 --> 00:33:36,179
This guitar is being made
not by man, but by machine.
603
00:33:36,181 --> 00:33:39,416
It's a process called cnc.
604
00:33:39,418 --> 00:33:42,786
Cnc is the name that we give
to computer numerical control,
605
00:33:42,788 --> 00:33:46,156
And it's the idea that we can
use automated control
606
00:33:46,158 --> 00:33:47,424
To control machine tools,
607
00:33:47,426 --> 00:33:51,328
Be that milling or lathes
or several others.
608
00:33:51,330 --> 00:33:53,497
Why it's really useful
is it means
609
00:33:53,499 --> 00:33:56,733
We can mill away complex
contoured shapes
610
00:33:56,735 --> 00:33:58,602
Like those
on the strandberg guitar
611
00:33:58,604 --> 00:34:01,138
Without having to have
human interference.
612
00:34:01,140 --> 00:34:05,108
♪♪
613
00:34:05,110 --> 00:34:07,344
Narrator:
Strandberg uses cnc
614
00:34:07,346 --> 00:34:09,713
Because they're making
a radically different
615
00:34:09,715 --> 00:34:10,914
Type of guitar.
616
00:34:10,916 --> 00:34:13,283
But the unusual
shape and design
617
00:34:13,285 --> 00:34:15,185
Are not there are just for show.
618
00:34:15,187 --> 00:34:18,488
Designer ola strandberg
has spent 12 years
619
00:34:18,490 --> 00:34:22,759
Developing a guitar that
he thinks not only sounds great,
620
00:34:22,761 --> 00:34:24,461
But should also help musicians
621
00:34:24,463 --> 00:34:27,497
Prevent repetitive
strain injury.
622
00:34:27,499 --> 00:34:30,200
Strandberg: All strandberg
guitars use our patented shape,
623
00:34:30,202 --> 00:34:33,570
Which is made
to reduce the stress
624
00:34:33,572 --> 00:34:35,872
On muscle joints and tendons
625
00:34:35,874 --> 00:34:38,375
And allow you to play
with a more relaxed hand.
626
00:34:38,377 --> 00:34:41,344
♪♪
627
00:34:41,346 --> 00:34:43,713
Which allows you
to practice more
628
00:34:43,715 --> 00:34:46,049
And become a better musician
that way.
629
00:34:46,051 --> 00:34:48,285
Rsi,
or repetitive strain injury,
630
00:34:48,287 --> 00:34:50,754
Is a massive problem
in the music industry.
631
00:34:50,756 --> 00:34:53,723
To reach elite status, you need
to practice for hours on end,
632
00:34:53,725 --> 00:34:56,460
And that means the same motions
over and over.
633
00:34:56,462 --> 00:34:59,062
Our bodies just can't
deal with that.
634
00:34:59,064 --> 00:35:01,598
A survey of american symphony
orchestra players
635
00:35:01,600 --> 00:35:06,269
Discovered that two-thirds
of them had suffered from rsi.
636
00:35:06,271 --> 00:35:09,840
Narrator: Strandberg uses cnc
not only to make the guitar
637
00:35:09,842 --> 00:35:11,942
More ergonomic
and user-friendly,
638
00:35:11,944 --> 00:35:14,277
But to drastically
reduce weight.
639
00:35:14,279 --> 00:35:16,780
Most guitarists perform
standing up
640
00:35:16,782 --> 00:35:19,483
So all the weight rests
on the shoulder.
641
00:35:19,485 --> 00:35:21,551
Compared to
many conventional guitars
642
00:35:21,553 --> 00:35:23,987
Weighing anything up
to eight pounds,
643
00:35:23,989 --> 00:35:27,390
The strandberg tips the scale
at just five.
644
00:35:27,392 --> 00:35:30,060
Ola strandberg believes
this lighter weight
645
00:35:30,062 --> 00:35:33,263
Is good for both the musician
and the music.
646
00:35:33,265 --> 00:35:35,432
So at the top
of the body portion,
647
00:35:35,434 --> 00:35:37,167
We cut this tone chamber
648
00:35:37,169 --> 00:35:39,369
Partly to reduce the weight,
649
00:35:39,371 --> 00:35:42,772
But also to introduce
the tonal characteristics
650
00:35:42,774 --> 00:35:45,308
Of a more lightweight
and resonant body.
651
00:35:46,478 --> 00:35:48,044
Narrator:
The main body is cut
652
00:35:48,046 --> 00:35:50,013
Next to a thinner
piece of wood.
653
00:35:50,015 --> 00:35:51,648
It's called the top,
654
00:35:51,650 --> 00:35:54,317
And will become the decorative
front of the guitar.
655
00:35:54,319 --> 00:35:56,853
The top is made from
flamed maple,
656
00:35:56,855 --> 00:36:00,490
A wood valued for
its attractive patterned grain.
657
00:36:00,492 --> 00:36:03,226
Once the top and body
are joined,
658
00:36:03,228 --> 00:36:06,696
It's time to cut inserts
for the electric controls --
659
00:36:06,698 --> 00:36:09,332
The pickups, tone,
and volume knobs
660
00:36:09,334 --> 00:36:11,401
And the groove to attach
the neck.
661
00:36:11,403 --> 00:36:14,337
And it has taken
some modern innovations
662
00:36:14,339 --> 00:36:18,308
To precisely match
ola's design.
663
00:36:18,310 --> 00:36:21,511
Strandberg: It is a challenge
for most guitar factories
664
00:36:21,513 --> 00:36:24,281
Because it requires
a lot of precision
665
00:36:24,283 --> 00:36:27,484
To actually obtain
the features that we want.
666
00:36:27,486 --> 00:36:29,986
♪♪
667
00:36:32,124 --> 00:36:34,558
♪♪
668
00:36:36,728 --> 00:36:39,629
Narrator: Japan's guitar valley,
matsumoto,
669
00:36:39,631 --> 00:36:43,233
Is home to the strandberg
guitar factory.
670
00:36:43,235 --> 00:36:46,303
Here, uniquely shaped
electric guitars
671
00:36:46,305 --> 00:36:50,340
Are made using the latest
digital technology.
672
00:36:50,342 --> 00:36:52,976
Overseeing
the strandberg operation
673
00:36:52,978 --> 00:36:55,478
Is nick "sugi" sugimoto.
674
00:36:55,480 --> 00:36:59,082
Sugi has been making guitars
since the 1970s
675
00:36:59,084 --> 00:37:02,085
For guitar legends
such as steve vai
676
00:37:02,087 --> 00:37:03,520
And george benson.
677
00:37:03,522 --> 00:37:06,223
He now works as a consultant
for strandberg
678
00:37:06,225 --> 00:37:08,158
And is a latter-day convert
679
00:37:08,160 --> 00:37:11,261
To using computers
to make great guitars.
680
00:37:11,263 --> 00:37:14,698
Sugimoto: It's really hard to
make this kind of instrument
681
00:37:14,700 --> 00:37:21,004
Because the neck back shape
is particularly,
682
00:37:21,006 --> 00:37:24,374
You know, really unique.
683
00:37:24,376 --> 00:37:27,611
If there's no cnc,
684
00:37:27,613 --> 00:37:31,114
Impossible to make
this kind of instrument.
685
00:37:32,684 --> 00:37:35,552
Narrator: Guitar production
may be based in japan,
686
00:37:35,554 --> 00:37:37,988
But the design
is the brainchild
687
00:37:37,990 --> 00:37:41,958
Of swedish national
ola strandberg.
688
00:37:41,960 --> 00:37:44,828
So what brought this
visionary scandinavian
689
00:37:44,830 --> 00:37:46,630
Halfway around the world
690
00:37:46,632 --> 00:37:50,800
To build his dream instrument
here in japan's guitar valley?
691
00:37:50,802 --> 00:37:53,937
Strandberg: It is a challenge
for most guitar factories
692
00:37:53,939 --> 00:37:56,706
Because it requires
a lot of precision
693
00:37:56,708 --> 00:38:01,478
To actually obtain
the features that we want.
694
00:38:01,480 --> 00:38:04,514
Narrator: Japanese artisans have
a long tradition of both
695
00:38:04,516 --> 00:38:07,784
Making stringed instruments
and working with wood.
696
00:38:07,786 --> 00:38:10,820
The two skills came together
here in matsumoto
697
00:38:10,822 --> 00:38:12,389
In the 1960s.
698
00:38:12,391 --> 00:38:14,024
With the rock and roll boom
in the '60s,
699
00:38:14,026 --> 00:38:16,359
Everybody wanted cheap guitars.
700
00:38:16,361 --> 00:38:20,463
Many japanese firms piled in,
making knock-off fenders,
701
00:38:20,465 --> 00:38:22,132
Gibsons, and so on.
702
00:38:22,134 --> 00:38:25,368
But some of these guitars
were so well done
703
00:38:25,370 --> 00:38:27,637
That manufacturers
in the states said,
704
00:38:27,639 --> 00:38:31,041
"we'll offer you a contract
to build the real thing."
705
00:38:31,043 --> 00:38:33,510
Narrator:
And for the guitar valley,
706
00:38:33,512 --> 00:38:35,612
The rest was history.
707
00:38:35,614 --> 00:38:38,114
This guitar is ready
for a lick of paint.
708
00:38:38,116 --> 00:38:41,217
That's a step too far for cnc.
709
00:38:41,219 --> 00:38:45,355
This instrument now needs
some good old human tlc.
710
00:38:45,357 --> 00:38:47,557
The top is sealed
and the rest of the body
711
00:38:47,559 --> 00:38:49,459
Is sprayed with lacquer.
712
00:38:49,461 --> 00:38:53,396
Next, several coats of stain
are applied to the top.
713
00:38:53,398 --> 00:38:56,800
The top is gently sanded
after each layer dries.
714
00:38:56,802 --> 00:39:00,737
This provides the optimum visual
effect from the wood grain.
715
00:39:00,739 --> 00:39:02,439
[ whirring ]
716
00:39:02,441 --> 00:39:06,343
The body is then given one
final clear coat, and polished.
717
00:39:06,345 --> 00:39:10,246
♪♪
718
00:39:12,751 --> 00:39:16,019
One of the most striking
features on the strandberg
719
00:39:16,021 --> 00:39:18,054
Is the revolutionary neck.
720
00:39:18,056 --> 00:39:19,756
On a conventional guitar,
721
00:39:19,758 --> 00:39:23,793
The strings are tuned at the top
of the neck, the headstock.
722
00:39:23,795 --> 00:39:26,730
Strandbergs don't have
a headstock.
723
00:39:26,732 --> 00:39:29,265
They're tuned lower down
at the bridge.
724
00:39:29,267 --> 00:39:33,603
Here, tuning can be comfortably
achieved by the picking hand.
725
00:39:33,605 --> 00:39:35,939
There's no need
to stretch out to tune
726
00:39:35,941 --> 00:39:37,440
At the end of the neck.
727
00:39:37,442 --> 00:39:39,909
The strandberg neck
doesn't just look different
728
00:39:39,911 --> 00:39:41,478
From the standard guitar.
729
00:39:41,480 --> 00:39:44,080
It's made in a totally
different way.
730
00:39:44,082 --> 00:39:47,617
Usually the neck is shaped
roughly and quickly by machine,
731
00:39:47,619 --> 00:39:50,286
Then finally shaped
by guitar craftsmen.
732
00:39:50,288 --> 00:39:52,055
On a strandberg,
733
00:39:52,057 --> 00:39:53,990
Three glued maple wood squares
734
00:39:53,992 --> 00:39:56,693
Are stuck together
to add strength
735
00:39:56,695 --> 00:39:59,496
And then routed
to make way for the truss rod.
736
00:39:59,498 --> 00:40:01,931
Like all wood, guitar necks
737
00:40:01,933 --> 00:40:04,434
Are prone to bending
due to humidity
738
00:40:04,436 --> 00:40:08,171
And the tension caused by
the stretched wire strings.
739
00:40:08,173 --> 00:40:10,640
The truss rod runs the length
of the neck
740
00:40:10,642 --> 00:40:13,243
To counter these strains.
741
00:40:13,245 --> 00:40:16,846
Pau ferro wood is now added
to make the fretboard
742
00:40:16,848 --> 00:40:19,382
Over which the strings
are placed.
743
00:40:19,384 --> 00:40:23,086
The back of the neck
is even more complex.
744
00:40:23,088 --> 00:40:25,455
A trapezoid shape is milled,
745
00:40:25,457 --> 00:40:29,125
Which strandberg maintains
results in far less stress
746
00:40:29,127 --> 00:40:32,695
On hand muscles,
joints, and tendons.
747
00:40:32,697 --> 00:40:36,166
This unconventional neck
needs an absolute precision
748
00:40:36,168 --> 00:40:37,934
That can only be achieved
749
00:40:37,936 --> 00:40:41,704
By cutting machines
linked to cnc programs.
750
00:40:41,706 --> 00:40:43,673
Strandberg: But because of this
complex profile,
751
00:40:43,675 --> 00:40:48,344
It requires much more accurate
processing on the machine.
752
00:40:48,346 --> 00:40:51,347
And then just the final,
very final finishing
753
00:40:51,349 --> 00:40:54,050
To be done
by traditional methods.
754
00:40:54,052 --> 00:40:57,287
It's one of the steps
that's taking a lot of effort
755
00:40:57,289 --> 00:41:02,826
To work with manufacturers
to really perfect this process.
756
00:41:02,828 --> 00:41:05,495
Narrator: Once the neck is
attached to the body,
757
00:41:05,497 --> 00:41:06,996
It's time to go electric
758
00:41:06,998 --> 00:41:10,366
And add the pickups,
strings, and controls.
759
00:41:10,368 --> 00:41:12,969
The high-tech approach
continues.
760
00:41:12,971 --> 00:41:15,872
Instead of standard metal
and plastics,
761
00:41:15,874 --> 00:41:19,576
Aircraft grade aluminum
is used on the pickups,
762
00:41:19,578 --> 00:41:22,178
And carbon fiber
for the pot, volume,
763
00:41:22,180 --> 00:41:26,082
And tone knobs and switch.
764
00:41:26,084 --> 00:41:30,820
In 2018, strandberg made
3,500 guitars,
765
00:41:30,822 --> 00:41:34,057
But orders are rapidly
outstripping production.
766
00:41:34,059 --> 00:41:37,126
Whether this popularity
is due to radical looks,
767
00:41:37,128 --> 00:41:40,163
The sound, or lightweight
ergonomic design --
768
00:41:40,165 --> 00:41:43,233
Or a combination of all three --
is unclear.
769
00:41:43,235 --> 00:41:46,869
But strandberg is rapidly
ramping up production
770
00:41:46,871 --> 00:41:48,738
To meet demand.
771
00:41:48,740 --> 00:41:51,407
This company is just
10 years old,
772
00:41:51,409 --> 00:41:53,810
But with its unique take
on the revamping
773
00:41:53,812 --> 00:41:57,747
Of a modern design icon,
the electric guitar,
774
00:41:57,749 --> 00:42:02,785
Strandberg definitely qualifies
as a super factory.