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00:00:01,936 --> 00:00:06,171
Narrator: THE SECRETS OF A
WORLD-FAMOUS SNACK ARE REVEALED.
2
00:00:06,173 --> 00:00:09,241
ROBOTS AND HUMANS
ARE WORKING IN TANDEM
3
00:00:09,243 --> 00:00:13,445
TO CREATE THIS SOPHISTICATED
LUXURY SPORTS CAR.
4
00:00:13,447 --> 00:00:15,781
MODERN TECHNOLOGY
IS BRINGING CHARACTERS
5
00:00:15,783 --> 00:00:20,352
FROM A POPULAR
ANIME TV SERIES TO LIFE.
6
00:00:20,354 --> 00:00:24,790
AND THIS EUROPEAN MANUFACTURER
IS FLUSHING OUT THE COMPETITION
7
00:00:24,792 --> 00:00:28,560
BY PUSHING THE BOUNDARIES
OF DESIGN AND ENGINEERING.
8
00:00:28,562 --> 00:00:31,997
THESE GROUNDBREAKING INNOVATIONS
ARE ALL TAKING PLACE
9
00:00:31,999 --> 00:00:35,167
INSIDE SOME OF THE MOST
INCREDIBLE FACTORIES
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00:00:35,169 --> 00:00:36,602
ON THE PLANET.
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-- Captions by VITAC --
www.vitac.com
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CAPTIONS PAID FOR BY
DISCOVERY COMMUNICATIONS
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LOCATED IN PERRY, GEORGIA,
IS THE FRITO-LAY FACTORY,
14
00:00:51,585 --> 00:00:55,854
THE WORLD'S LEADING
SUPPLIER OF POTATO CHIPS.
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IT'S HERE WHERE THE COMPANY'S
FAMOUS CHIP BRANDS, DORITOS,
16
00:00:59,860 --> 00:01:02,361
CHEETOS, FRITOS, AND LAYS
17
00:01:02,363 --> 00:01:06,398
ARE PRODUCED IN OVER
160 FLAVOR VARIETIES.
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00:01:06,400 --> 00:01:11,103
Russell:
POTATO CHIPS ARE MASSIVE, AND
LAYS ARE A BIG PLAYER IN THIS.
19
00:01:11,105 --> 00:01:14,807
LAYS HAVE BEEN AROUND
FOR ABOUT 80 YEARS.
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Narrator: TODAY, FRITO-LAYS IS
ONE OF THE MOST RECOGNIZABLE
21
00:01:18,179 --> 00:01:20,145
CHIP BRANDS IN THE WORLD,
22
00:01:20,147 --> 00:01:23,882
CONTROLLING 35%
OF THE SNACK CHIP MARKET.
23
00:01:23,884 --> 00:01:27,953
BUT THIS BUSINESS GREW
FROM VERY HUMBLE BEGINNINGS.
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00:01:27,955 --> 00:01:31,890
SO WHO INVENTED THE POTATO CHIP?
GOOD QUESTION.
25
00:01:31,892 --> 00:01:35,260
SOME SAY IT WAS A CHEF
NAMED GEORGE CRUM
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00:01:35,262 --> 00:01:38,564
IN NEW YORK STATE
IN THE 1850s.
27
00:01:38,566 --> 00:01:40,999
SO WHAT WE DO KNOW
IS THAT HERMAN LAY STARTED
28
00:01:41,001 --> 00:01:46,105
PEDALING CHIPS OUT OF HIS
MODEL A FORD IN 1931.
29
00:01:46,107 --> 00:01:51,210
SOON HE HAD HIS FIRST FACTORY,
AND THE REST IS HISTORY.
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00:01:51,212 --> 00:01:52,744
Narrator: FOR MORE
THAN 20 YEARS,
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THE PERRY FACILITY HAS BEEN
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00:01:54,248 --> 00:01:56,115
A MAJOR PART
OF THE COMMUNITY
33
00:01:56,117 --> 00:01:57,950
IN THIS PART OF THE STATE.
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AT NEARLY 990,000 SQUARE FEET,
35
00:02:01,655 --> 00:02:04,890
THE FACTORY SITS
ON 1,500 ACRES OF LAND.
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IT'S ALSO THE FIRST FACILITY
IN GEORGIA TO BE AWARDED
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00:02:08,195 --> 00:02:09,928
A LEAD CERTIFICATION,
38
00:02:09,930 --> 00:02:14,266
RECOGNIZING IT AS AN
ENVIRONMENTALLY FRIENDLY SITE.
39
00:02:14,268 --> 00:02:16,802
BUT THE KEY TO
THIS FACTORY'S SUCCESS
40
00:02:16,804 --> 00:02:19,471
IS NOT ONLY ITS UNIQUE FACILITY,
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00:02:19,473 --> 00:02:23,842
IT'S ALSO WHAT'S BEING
MANUFACTURED INSIDE.
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00:02:23,844 --> 00:02:27,513
AT FRITO-LAY,
QUALITY BEGINS AT THE FARM,
43
00:02:27,515 --> 00:02:31,583
THIS FACTORY IMPORTS POTATOES
FROM 120 FARMS
44
00:02:31,585 --> 00:02:35,154
ACROSS 25 DIFFERENT STATES.
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JUST LIKE THEIR
BUILDING STANDARDS,
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QUALITY CONTINUES THROUGHOUT
THE MANUFACTURING PROCESS
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THROUGH VITAL
VISUAL INSPECTIONS,
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00:02:43,130 --> 00:02:45,097
Maxwell: ALL OUR POTATOES
GET A QUALITY CHECK.
49
00:02:45,099 --> 00:02:47,966
WE'RE LOOKING AT APPEARANCE.
WE'RE LOOKING AT SIZE.
50
00:02:47,968 --> 00:02:50,602
COLOR, TEMPERATURE,
AND WE HAVE SPECIFICATIONS
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FOR ALL OF THOSE THINGS,
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Narrator: ONCE THEY
PASS INSPECTION,
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THE POTATOES ARE WASHED
AND PEELED
54
00:02:56,810 --> 00:02:59,044
USING SPECIALIZED EQUIPMENT.
55
00:03:23,270 --> 00:03:26,238
HERMAN LAY DEVELOPED
THE MECHANICAL POTATO PEELER
56
00:03:26,240 --> 00:03:28,707
JUST UNDER 100 YEARS AGO,
57
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THAT WAS A GAME CHANGER.
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LAYS HAVE NEVER LOOKED BACK.
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Narrator:
ONCE THE POTATOES ARE CLEANED,
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THEY MOVE DOWN A BELT
TO A SLICING MACHINE.
61
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THE MACHINE'S RAZOR-SHARP BLADES
CUT THE POTATOES INTO A VARIETY
62
00:03:44,191 --> 00:03:48,260
OF DIFFERENT THICKNESSES
AND SHAPES.
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00:03:48,262 --> 00:03:51,964
INSIDE THE SLICING MACHINE,
THE CENTRIFUGAL FORCE CREATED
64
00:03:51,966 --> 00:03:56,635
BY THE SPINNING DRUMS THROWS
THE POTATOES AGAINST THE BLADES,
65
00:03:56,637 --> 00:04:00,072
RAPIDLY SLICING THEM
INTO VERY THIN PIECES.
66
00:04:04,345 --> 00:04:06,311
NEXT, THE POTATO SLICES
67
00:04:06,313 --> 00:04:11,149
ARE WASHED TO REMOVE
ANY REMAINING STARCH.
68
00:04:11,151 --> 00:04:14,353
THEN DRIED TO REDUCE MOISTURE.
69
00:04:14,355 --> 00:04:17,322
NOW THE CHIPS
ARE READY TO BE FRIED.
70
00:04:17,324 --> 00:04:20,392
THE CHIPS ARE FRIED
IN CANOLA OIL
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00:04:20,394 --> 00:04:23,662
IN A TEMP ABOUT
350 DEGREES.
72
00:04:23,664 --> 00:04:27,633
AND THAT PROCESS, AS IT COMES,
IT TAKES ABOUT THREE MINUTES
73
00:04:27,635 --> 00:04:31,870
AS IT GOES FROM THE SLICING
PROCESS TO THE FRYING PROCESS.
74
00:04:31,872 --> 00:04:33,705
AS THEY GO THROUGH
THE FRYING PROCESS,
75
00:04:33,707 --> 00:04:36,808
THIS WOULD BE THE
FINISHED PRODUCT.
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00:04:36,810 --> 00:04:39,378
Narrator: AFTER FRYING,
THE CHIPS ARE SALTED,
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FLAVORED, AND FED INTO LARGE
SORTING CONTAINERS.
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EACH CONTAINER AUTOMATICALLY
MEASURES OUT THE CHIPS
79
00:04:47,688 --> 00:04:51,156
INTO HALF POUND PORTIONS.
80
00:04:51,158 --> 00:04:55,661
THEN THEY'RE DISTRIBUTED
INTO INDIVIDUAL PACKAGES.
81
00:04:55,663 --> 00:04:58,463
AND FRITO-LAY'S SECRET TO
KEEPING THE CHIPS FRESH
82
00:04:58,465 --> 00:05:01,333
CAN BE FOUND INSIDE THE BAG.
83
00:05:01,335 --> 00:05:04,603
NITROGEN IS PUMPED INTO THE BAGS
FOR TWO REASONS.
84
00:05:04,605 --> 00:05:07,572
IT REDUCES THE AMOUNT
OF OXYGEN IN THE BAGS.
85
00:05:07,574 --> 00:05:10,709
AND THAT OXYGEN
CAN INCREASE FOOD DECAY.
86
00:05:10,711 --> 00:05:13,845
AND THEN THE SECOND REASON
IS IT CREATES A CUSHION.
87
00:05:13,847 --> 00:05:17,049
AND THIS MEANS THAT THE CRISPS
AREN'T SMASHED TO SMITHEREENS
88
00:05:17,051 --> 00:05:18,850
BY THE TIME THEY REACH YOU.
89
00:05:18,852 --> 00:05:20,585
Narrator: BACK
ON THE ASSEMBLY LINE,
90
00:05:20,587 --> 00:05:25,223
A TECHNICIAN THOROUGHLY INSPECTS
THE OUTSIDE OF EACH BAG.
91
00:05:25,225 --> 00:05:28,960
I'M DOING MY QUALITY
CHECK IN THE MORNING,
92
00:05:28,962 --> 00:05:30,662
I'M GOING TO CHECK OUT
MY BACK SEAL,
93
00:05:30,664 --> 00:05:32,230
MAKE SURE IT'S SOLID.
94
00:05:32,232 --> 00:05:35,500
THE SEAL'S INTEGRITY
IS GOOD,
95
00:05:35,502 --> 00:05:37,636
THAT I HAVE A PRICE
AND DATE ON HERE,
96
00:05:37,638 --> 00:05:40,339
AND THAT IT'S LEGIBLE.
97
00:05:40,341 --> 00:05:43,742
AND ALSO THAT THE GRAPHICS
ARE NOT TWISTED
98
00:05:43,744 --> 00:05:47,179
OR ANYTHING LIKE THAT.
99
00:05:47,181 --> 00:05:49,981
Narrator: ONCE THE BAGS ARE
SEALED, THEY'RE TRANSPORTED
100
00:05:49,983 --> 00:05:55,087
TO THE COMPANY'S 700,000
SQUARE FOOT DISTRIBUTION CENTER.
101
00:05:55,089 --> 00:05:58,190
HERE, MORE THAN 1,250
OPERATORS WORK
102
00:05:58,192 --> 00:06:01,860
WITH SPECIAL PURPOSE EQUIPMENT
TO STOCK AND PROCESS ORDERS
103
00:06:01,862 --> 00:06:04,429
FOR RETAILERS
ALL OVER THE COUNTRY.
104
00:06:06,500 --> 00:06:08,500
SO THIS WEEK ALONE,
105
00:06:08,502 --> 00:06:13,338
FRITO-LAY NATIONALLY WILL MAKE
HALF A MILLION SERVICE CALLS
106
00:06:13,340 --> 00:06:17,676
AND WILL MAKE THOSE SERVICE
CALLS OVER 15,000 ROUTES.
107
00:06:17,678 --> 00:06:19,711
MUCH OF THAT PRODUCT WILL GET
INTO THE MARKETPLACE
108
00:06:19,713 --> 00:06:22,948
ON OVER THE ROAD VEHICLES
AND OUR ENTIRE FLEET OF ASSETS
109
00:06:22,950 --> 00:06:26,852
IS 23,000 IN FRITO-LAY
IN THE UNITED STATES.
110
00:06:26,854 --> 00:06:29,488
THE COMPANY HAS ONE OF THE
LARGEST PRIVATE VEHICLE FLEETS
111
00:06:29,490 --> 00:06:31,590
IN THE U.S.,
WHICH IT USES TO TRANSPORT
112
00:06:31,592 --> 00:06:36,762
THE GOODS TO POINTS OF SALE --
GROCERY STORES AND SUPERMARKETS.
113
00:06:36,764 --> 00:06:39,798
Narrator: POTATO CHIPS REPRESENT
ONE OF THE MOST POPULAR SNACKS
114
00:06:39,800 --> 00:06:42,134
CONSUMED ACROSS THE GLOBE.
115
00:06:42,136 --> 00:06:43,668
WITH A PROJECTED MARKET VALUE
116
00:06:43,670 --> 00:06:47,406
SET TO REACH $35 BILLION
BY 2024,
117
00:06:47,408 --> 00:06:49,841
THERE'S NO QUESTION
THAT THIS SALTY SNACK
118
00:06:49,843 --> 00:06:52,344
IS IN HIGH DEMAND IN THE U.S.
119
00:06:52,346 --> 00:06:56,381
AND RECENT STUDIES SUGGEST THE
DEMAND FROM EMERGING ECONOMIES
120
00:06:56,383 --> 00:06:58,750
IS ALSO ON THE RISE.
121
00:06:58,752 --> 00:07:02,621
UP UNTIL NOW, POTATO CHIPS
HAVE MAINLY BEEN CONSUMED
122
00:07:02,623 --> 00:07:04,055
IN THE RICHER COUNTRIES,
123
00:07:04,057 --> 00:07:07,626
THE SO-CALLED DEVELOPED
WORLD OF THE WEST.
124
00:07:07,628 --> 00:07:09,961
BUT THAT IS LIKELY TO CHANGE
IN THE FUTURE
125
00:07:09,963 --> 00:07:11,263
AS DEVELOPING COUNTRIES
126
00:07:11,265 --> 00:07:15,133
ARE SEEN AS BEING
THE NEXT BIG GROWTH AREA.
127
00:07:15,135 --> 00:07:17,569
Narrator:
FOR OVER 75 YEARS,
128
00:07:17,571 --> 00:07:21,206
FRITO-LAY HAS BEEN
MANUFACTURING SATISFYING SNACKS
129
00:07:21,208 --> 00:07:24,743
TO PEOPLE AND RETAILERS
AROUND THE WORLD.
130
00:07:24,745 --> 00:07:29,281
TODAY, THE PERRY FACILITY
PRODUCES OVER 1.7 BILLION
131
00:07:29,283 --> 00:07:30,949
BAGS OF CHIPS A YEAR.
132
00:07:30,951 --> 00:07:35,320
THE WORKFORCE IS DEDICATED TO
PRODUCING HIGH-QUALITY SNACKS,
133
00:07:35,322 --> 00:07:38,924
AND IT'S THEIR ABILITY TO MIX
PRODUCTIVITY WITH MODERNITY
134
00:07:38,926 --> 00:07:42,727
THAT MAKES THIS FACTORY
A SUPER FACTORY.
135
00:07:46,567 --> 00:07:49,267
COMING UP, NEW TECHNOLOGY
IS COMBINED
136
00:07:49,269 --> 00:07:51,470
WITH ITALIAN CRAFTSMANSHIP
137
00:07:51,472 --> 00:07:55,607
TO PRODUCE THE WORLD'S
MOST DISTINGUISHED SPORTS CAR.
138
00:07:55,609 --> 00:07:59,211
ONE OF THE KEY POINTS FOR US
IS LUXURY, BECAUSE LUXURY
139
00:07:59,213 --> 00:08:04,015
MEANS THE HIGHEST STANDARDS
OF THE MANUFACTURING.
140
00:08:04,017 --> 00:08:06,418
Narrator:
AND LATER, IN JAPAN,
141
00:08:06,420 --> 00:08:09,621
THIS SUPER FACTORY
IS OPTIMIZING PRODUCTIVITY
142
00:08:09,623 --> 00:08:13,058
BY UTILIZING THE LATEST
AUTOMATED TECHNOLOGIES
143
00:08:13,060 --> 00:08:17,395
TO CREATE TOYS FOR
ANIME FANS ALL OVER THE WORLD.
144
00:08:19,733 --> 00:08:24,836
¶¶
145
00:08:24,838 --> 00:08:30,141
¶¶
146
00:08:30,143 --> 00:08:32,310
Narrator: SURROUNDED BY
THE BUSTLING CITY STREETS
147
00:08:32,312 --> 00:08:33,812
OF TURIN, ITALY,
148
00:08:33,814 --> 00:08:38,783
IS A FACTORY PRODUCING
A LEGENDARY SPORTS CAR.
149
00:08:38,785 --> 00:08:42,587
FOR OVER A CENTURY,
MASERATI HAS BEEN MANUFACTURING
150
00:08:42,589 --> 00:08:44,589
BEAUTIFULLY DESIGNED VEHICLES
151
00:08:44,591 --> 00:08:47,826
EQUIPPED WITH A HIGH
PERFORMANCE RACING ENGINE.
152
00:08:47,828 --> 00:08:51,162
NOW IN ITS SIXTH GENERATION,
THE QUATTROPORTE
153
00:08:51,164 --> 00:08:53,732
IS MASERATI'S
TOP-SELLING VEHICLE
154
00:08:53,734 --> 00:08:56,935
AND IS ONE OF THE MOST
LUXURIOUS CARS IN PRODUCTION
155
00:08:56,937 --> 00:09:00,105
ANYWHERE IN THE WORLD.
156
00:09:00,107 --> 00:09:02,674
ONE OF THE KEY POINTS FOR US
IS LUXURY,
157
00:09:02,676 --> 00:09:06,945
BECAUSE LUXURY MEANS THE
HIGHEST STANDARDS OF MATERIALS,
158
00:09:06,947 --> 00:09:10,015
HIGHEST STANDARDS
OF THE MANUFACTURING.
159
00:09:10,017 --> 00:09:11,516
Narrator:
LIKE ITS PREDECESSORS.
160
00:09:11,518 --> 00:09:14,553
THE QUATTROPORTE'S DISTINCTIVE
SLEEK DESIGN,
161
00:09:14,555 --> 00:09:18,223
HANDCRAFTED INTERIORS,
AND POWERFUL RACING ENGINE
162
00:09:18,225 --> 00:09:22,427
ARE WHAT MAKES IT A CUT ABOVE
ITS LUXURY SEDAN COMPETITORS.
163
00:09:22,429 --> 00:09:24,863
THE MASERATI BROTHERS
SET UP A WORKSHOP
164
00:09:24,865 --> 00:09:28,733
FOR EARLY RACING CARS IN 1914,
165
00:09:28,735 --> 00:09:33,004
AND THEY DOMINATED RACETRACKS
FOR THE NEXT 50 YEARS.
166
00:09:33,006 --> 00:09:38,476
IN 1963, THEY UNVEILED
THE QUATTROPORTE SPORTS SEDAN,
167
00:09:38,478 --> 00:09:43,081
THE FASTEST FOUR-DOOR CAR
IN THE WORLD.
168
00:09:43,083 --> 00:09:45,350
Narrator: THE QUATTROPORTE
IS DESIGNED, PRODUCED,
169
00:09:45,352 --> 00:09:48,653
AND ASSEMBLED HERE
AT THE TURIN MANUFACTURING HUB
170
00:09:48,655 --> 00:09:50,722
LOCATED IN NORTHERN ITALY,
171
00:09:50,724 --> 00:09:53,058
BUT IT'S NOT THE ONLY
VEHICLE MANUFACTURED
172
00:09:53,060 --> 00:09:55,327
AT THIS MASSIVE FACILITY.
173
00:09:55,329 --> 00:09:59,331
IN 1993, FIAT CHRYSLER
ACQUIRED MASERATI
174
00:09:59,333 --> 00:10:02,601
AND FOUR YEARS LATER
TURNED MANAGEMENT OF MASERATI
175
00:10:02,603 --> 00:10:04,202
OVER TO FERRARI.
176
00:10:04,204 --> 00:10:07,372
A LOT OF THE FAMOUS
MANUFACTURERS, ROLLS-ROYCE,
177
00:10:07,374 --> 00:10:10,108
DAIMLER, AND MANY ARE ACTUALLY
OWNED BY CONGLOMERATES,
178
00:10:10,110 --> 00:10:12,077
AND THAT'S BECAUSE
OF ECONOMIES OF SCALE.
179
00:10:12,079 --> 00:10:14,946
SO MASERATI ARE OWNED
BY FIAT CHRYSLER,
180
00:10:14,948 --> 00:10:18,717
AS ARE ALFA ROMEO AND FERRARI.
181
00:10:18,719 --> 00:10:21,753
Narrator: THIS CONSOLIDATION
MEANT THAT ALL THREE BRANDS
182
00:10:21,755 --> 00:10:24,255
WOULD BE PRODUCED
WITH THE SAME TECHNOLOGY
183
00:10:24,257 --> 00:10:27,492
AND THAT MASERATI SEDANS
WOULD NOW BE BUILT
184
00:10:27,494 --> 00:10:29,894
WITH FERRARI RACING ENGINES.
185
00:10:29,896 --> 00:10:31,796
TODAY, MASERATI
186
00:10:31,798 --> 00:10:35,734
IS THE DESIGNATED
LUXURY BRAND OF FIAT.
187
00:10:35,736 --> 00:10:40,105
EVERY SINGLE MASERATI
IS A WORK OF ART MADE BY PEOPLE.
188
00:10:40,107 --> 00:10:42,073
THIS SUCH CRAFT WORK.
189
00:10:42,075 --> 00:10:45,243
Narrator: TO UPHOLD THE
STANDARDS OF THE MASERATI BRAND,
190
00:10:45,245 --> 00:10:48,747
THE ASSEMBLY PROCESS IS DESIGNED
TO ELEVATE MODERN TECHNOLOGIES
191
00:10:48,749 --> 00:10:52,884
WITH DECADES
OF ITALIAN CRAFTSMANSHIP.
192
00:10:52,886 --> 00:10:56,021
IN MY OPINION, HERE WE HAVE
THE PERFECT MARRIAGE
193
00:10:56,023 --> 00:10:58,757
BETWEEN MEN AND AUTOMATION
194
00:10:58,759 --> 00:11:02,727
BECAUSE THERE ARE SOMETHING
THAT THE ROBOT CANNOT GIVE.
195
00:11:02,729 --> 00:11:06,598
THE ATTENTION TO
EACH SINGLE DETAIL,
196
00:11:06,600 --> 00:11:11,703
AND ONLY A HUMAN BEING
CAN DO THAT.
197
00:11:11,705 --> 00:11:15,540
Narrator:
HERE, ASSEMBLY STATIONS
ARE ERGONOMICALLY DESIGNED
198
00:11:15,542 --> 00:11:17,108
TO ENSURE EVERY PROCESS
199
00:11:17,110 --> 00:11:20,812
IS EASILY ACCESSIBLE
FOR THE WORKFORCE.
200
00:11:20,814 --> 00:11:22,881
SO A LOT OF THOUGHT HAS GONE
INTO DESIGNING
201
00:11:22,883 --> 00:11:25,016
ERGONOMIC ASSEMBLY LINES
202
00:11:25,018 --> 00:11:28,687
DESIGNED AND STRUCTURED SO THAT
WORKERS DON'T STRETCH THEMSELVES
203
00:11:28,689 --> 00:11:32,624
OR TWIST TOO MUCH AND INCUR
REPETITIVE STRAIN INJURY.
204
00:11:32,626 --> 00:11:34,693
THE ULTIMATE AMBITION
IS TO AVOID PEOPLE
205
00:11:34,695 --> 00:11:36,828
HURTING THEMSELVES AT WORK.
206
00:11:36,830 --> 00:11:38,196
Narrator:
MAKING A QUATTROPORTE
207
00:11:38,198 --> 00:11:40,432
BEGINS WITH THE CHASSIS
ASSEMBLY.
208
00:11:40,434 --> 00:11:42,967
THE CHASSIS IS BUILT AROUND
A RIGID AND SECURE
209
00:11:42,969 --> 00:11:45,270
STEEL SAFETY STOW
210
00:11:45,272 --> 00:11:48,406
MADE WITH STEEL
AND ALUMINUM ALLOYS.
211
00:11:48,408 --> 00:11:50,341
THE FRONT OF THE CHASSIS
IS BUILT AROUND
212
00:11:50,343 --> 00:11:52,043
AN ALUMINUM CASTING,
213
00:11:52,045 --> 00:11:55,714
WHILE THE BACK IS MADE
FROM ROLLED STEEL.
214
00:11:55,716 --> 00:11:58,883
EVERY SINGLE PART OF HOW
A VEHICLE PERFORMS
215
00:11:58,885 --> 00:12:02,087
CAN BE ATTRIBUTED
TO ITS WEIGHT DISTRIBUTION.
216
00:12:02,089 --> 00:12:05,090
A CAR THAT IS LIGHTER IN WEIGHT
IS ACTUALLY MORE FUEL EFFICIENT.
217
00:12:05,092 --> 00:12:06,991
MAGNESIUM IS PARTICULARLY
GOOD AT THIS.
218
00:12:06,993 --> 00:12:09,260
IT'S 36% LIGHTER
THAN ALUMINUM
219
00:12:09,262 --> 00:12:11,896
AND A WHOPPING 78%
LIGHTER THAN STEEL.
220
00:12:11,898 --> 00:12:14,299
LESS FUEL BEING USED
MEANS LESS EMISSIONS.
221
00:12:14,301 --> 00:12:17,135
Narrator: AS SOON AS THE CHASSIS
ARRIVES ON THE PRODUCTION LINE,
222
00:12:17,137 --> 00:12:20,305
THE TEAM GETS TO WORK
ASSEMBLING A CAR AROUND THIS
223
00:12:20,307 --> 00:12:23,241
ONE ESSENTIAL BUILDING BLOCK.
224
00:12:23,243 --> 00:12:25,410
THE SECRET TO PAINTING
A MASERATI
225
00:12:25,412 --> 00:12:28,513
IS IN THIS TECHNOLOGICALLY
ADVANCED PROCESS.
226
00:12:28,515 --> 00:12:31,082
ONCE ASSEMBLED, THE BODY
IS COATED IN A FLUID
227
00:12:31,084 --> 00:12:34,219
THAT PROTECTS IT FROM
CORROSION AND OXIDIZATION.
228
00:12:44,498 --> 00:12:47,499
NEXT, THE FRAMEWORK MOVES DOWN
THE ASSEMBLY LINE
229
00:12:47,501 --> 00:12:50,535
TOWARDS A DIP TANK.
230
00:12:50,537 --> 00:12:53,705
SUSPENDED BY AN ELECTRICALLY
CHARGED CHAIN,
231
00:12:53,707 --> 00:12:56,875
THE BODY IS SUBMERGED
INTO A PAINT SOLID MIXTURE
232
00:12:56,877 --> 00:13:00,345
MADE UP OF SOLVENTS,
RESIN, AND WATER.
233
00:13:00,347 --> 00:13:02,781
AS THE BODY MOVES
INTO THE FLUID,
234
00:13:02,783 --> 00:13:07,552
THE PAINT IS DEPOSITED ONTO THE
CAR THROUGH AN ELECTRIC CURRENT.
235
00:13:07,554 --> 00:13:10,955
THIS PROCESS
IS CALLED CATAPHORESIS.
236
00:13:33,280 --> 00:13:36,080
AFTER IT'S TREATED,
THE BODY IS HEATED
237
00:13:36,082 --> 00:13:42,720
IN A GIANT 130-FOOT OVEN
AT 375 DEGREES FOR 30 MINUTES.
238
00:13:42,722 --> 00:13:45,356
THE EXTREME HEAT
SOLIDIFIES THE PAINT
239
00:13:45,358 --> 00:13:48,293
TO ENSURE MAXIMUM PERFORMANCE.
240
00:13:48,295 --> 00:13:50,795
ONCE THE PROTECTIVE LAYER
HAS HARDENED,
241
00:13:50,797 --> 00:13:53,231
ALL REMAINING CONTAMINANTS
ARE REMOVED
242
00:13:53,233 --> 00:13:57,402
USING A NONTRADITIONAL BRUSH
MADE OF OSTRICH FEATHERS.
243
00:13:57,404 --> 00:14:00,071
YOU MIGHT WONDER WHY WE USE
OSTRICH FEATHERS
244
00:14:00,073 --> 00:14:02,740
WELL, OSTRICH FEATHERS
HAVE AN INNATE STATIC CHARGE
245
00:14:02,742 --> 00:14:05,643
NOT FOUND IN OTHER FEATHERS,
WHICH MAKES THEM REMARKABLY GOOD
246
00:14:05,645 --> 00:14:08,847
AT PICKING UP VERY FINE
PARTICLES OF DUST.
247
00:14:08,849 --> 00:14:11,683
Narrator: NOW IT'S READY
TO BE PAINTED.
248
00:14:11,685 --> 00:14:15,653
FIRST, AIR PAINT ATOMIZERS
APPLY A CODE OF PRIME.
249
00:14:29,402 --> 00:14:35,039
IT TAKES JUST A FEW MINUTES
TO PAINT A TYPICAL MASERATI CAR.
250
00:14:35,041 --> 00:14:37,609
AS THE CAR MOVES DOWN
THE ASSEMBLY LINE,
251
00:14:37,611 --> 00:14:39,878
A TOP COAT OF PAINT IS APPLIED.
252
00:14:42,015 --> 00:14:45,717
AN AIR PAINT ATOMIZER
USES AERODYNAMIC FORCE
253
00:14:45,719 --> 00:14:49,721
TO PUSH THE PAINT
ONTO THE VEHICLE.
254
00:14:49,723 --> 00:14:51,956
THE PAINT PARTICLES
SCATTER AROUND
255
00:14:51,958 --> 00:14:55,927
AS THEY BOUNCE OFF THE SURFACE
AND INTO THE AIR.
256
00:14:55,929 --> 00:15:00,164
THE RESULT, A PERFECTLY SMOOTH
COAT OF PAINT.
257
00:15:00,166 --> 00:15:03,234
NOW A LAYER OF CLEAR LACQUER
IS APPLIED
258
00:15:03,236 --> 00:15:06,104
TO GIVE THE CAR
AN EXTRA GLOSSY SHEEN.
259
00:15:09,109 --> 00:15:11,576
BEFORE IT'S DELIVERED
TO THE ASSEMBLY FLOOR,
260
00:15:11,578 --> 00:15:15,446
TECHNICIANS INSPECT THE FINISH
FOR ANY IMPERFECTIONS.
261
00:15:15,448 --> 00:15:17,649
THE VALUES LEARNED
OUT ON THE RACETRACK
262
00:15:17,651 --> 00:15:20,285
ARE APPLIED
ON THE FACTORY FLOOR.
263
00:15:20,287 --> 00:15:24,689
HERE, AN EMPTY PAINTED SHELL
WILL BECOME A MASERATI.
264
00:15:52,619 --> 00:15:56,054
THIS IS THE FIRST OF 24
ASSEMBLY STATIONS,
265
00:15:56,056 --> 00:15:59,824
WHERE THE PURSUIT OF LUXURY
MIXES WITH EFFICIENCY.
266
00:15:59,826 --> 00:16:01,426
EACH CAR SPENDS NO LONGER
267
00:16:01,428 --> 00:16:06,097
THAN 37 MINUTES
AT EACH STATION.
268
00:16:06,099 --> 00:16:09,901
FROM THE INTERIOR FINISH
TO THE LEATHER AND PAINT WORK,
269
00:16:09,903 --> 00:16:12,470
EVERY QUATTROPORTE
BUILT IN THIS FACTORY
270
00:16:12,472 --> 00:16:16,841
IS CUSTOMIZED BASED
ON THE REQUESTS OF THE CONSUMER.
271
00:16:16,843 --> 00:16:21,079
THIS IS WHAT GIVES MASERATI
ITS EXCLUSIVE EDGE.
272
00:16:21,081 --> 00:16:23,181
Meccia:
IN TERMS OF CUSTOMIZATION,
273
00:16:23,183 --> 00:16:27,118
I WOULD SAY 100%
CUSTOMIZABLE.
274
00:16:27,120 --> 00:16:32,523
MORE THAN 1.5 TRILLION
POSSIBLE DIFFERENT COMBINATION.
275
00:16:32,525 --> 00:16:35,693
THAT, OF COURSE, IS TRANSFORMED
FROM A COMMERCIAL STANDPOINT,
276
00:16:35,695 --> 00:16:39,364
NOT SO EASY TO MANAGE
IN TERMS OF MANUFACTURING,
277
00:16:39,366 --> 00:16:41,466
Narrator: BUT THERE'S STILL MORE
TO BE ASSEMBLED
278
00:16:41,468 --> 00:16:45,803
BEFORE THIS LUXURY VEHICLE
IS READY TO HIT THE ROAD.
279
00:16:45,805 --> 00:16:49,273
AND TO DO SO,
IT'LL TAKE BOTH MAN AND MACHINE
280
00:16:49,275 --> 00:16:53,845
WORKING TOGETHER TO EXECUTE
EACH STEP TO PERFECTION.
281
00:16:55,582 --> 00:17:00,551
¶¶
282
00:17:00,553 --> 00:17:04,822
Narrator: LOCATED IN TURIN,
ITALY, IS THE MASERATI FACTORY,
283
00:17:04,824 --> 00:17:09,427
THE WORLD'S LEADING MANUFACTURER
OF LUXURY SPORTS CARS.
284
00:17:09,429 --> 00:17:12,497
FOR OVER A CENTURY,
THIS LEGENDARY COMPANY
285
00:17:12,499 --> 00:17:15,366
HAS BEEN AT THE FOREFRONT
OF THE INDUSTRY,
286
00:17:15,368 --> 00:17:17,769
PRODUCING
HIGH-PERFORMANCE VEHICLES
287
00:17:17,771 --> 00:17:20,138
BUILT WITH RACING ENGINES.
288
00:17:22,242 --> 00:17:25,676
ON THE ASSEMBLY FLOOR,
TECHNICIANS GUIDE THE DASHBOARD
289
00:17:25,678 --> 00:17:28,212
THROUGH A MECHANICAL
ASSEMBLY PROCESS,
290
00:17:28,214 --> 00:17:31,716
BUT THIS IS
NO ORDINARY DASHBOARD.
291
00:17:31,718 --> 00:17:35,787
IT'S UPHOLSTERED IN FINE LEATHER
AND MADE FROM MAGNESIUM,
292
00:17:35,789 --> 00:17:38,289
MAKING IT BOTH STRONG
AND LIGHTWEIGHT.
293
00:17:58,244 --> 00:18:02,280
ONCE THE DASHBOARD IS ASSEMBLED,
TECHNICIANS CONNECT THE WIRING.
294
00:18:02,282 --> 00:18:07,985
IT'S ESSENTIAL THAT THIS STEP
IS ALL DONE BY HAND.
295
00:18:07,987 --> 00:18:11,889
NEXT, A MACHINE INSTALLS
THE WINDSHIELD.
296
00:18:11,891 --> 00:18:15,993
SUCTION CUPS LIFT THE GLASS
BEFORE APPLYING A SEALANT,
297
00:18:15,995 --> 00:18:19,197
LASER SENSORS MEASURE
THE OPENING IN THE BODY
298
00:18:19,199 --> 00:18:21,566
AND PRECISELY SECURE IT
INTO PLACE.
299
00:18:32,679 --> 00:18:36,714
THEN THE CAR MOVES FROM THE TRIM
LINE ONTO THE CHASSIS LINE.
300
00:18:51,564 --> 00:18:54,532
NOW THE HEART OF THE CAR
IS INSTALLED.
301
00:18:54,534 --> 00:19:00,071
THIS INCREDIBLY POWERFUL
350 HORSEPOWER FERRARI ENGINE
302
00:19:00,073 --> 00:19:03,040
CAN GO FROM ZERO
TO 60 MILES PER HOUR
303
00:19:03,042 --> 00:19:06,477
IN JUST 5.5 SECONDS.
304
00:19:06,479 --> 00:19:11,582
NEXT, THE BODY OF THE CAR
AND ENGINE ARE FITTED TOGETHER.
305
00:19:11,584 --> 00:19:14,485
FIRST, A TEAM
BUILDS THE DRIVETRAIN,
306
00:19:14,487 --> 00:19:17,321
WHICH IS MADE UP
OF THE ENGINE, GEARBOX,
307
00:19:17,323 --> 00:19:21,592
SHOCK ABSORBERS, FRONT EXHAUST
SYSTEM, AND BRAKES.
308
00:19:21,594 --> 00:19:24,729
ALL COMPONENTS ARE PLACED
INTO AN ASSEMBLY JIG
309
00:19:24,731 --> 00:19:26,697
THAT TRANSPORTS
THE MECHANICAL ELEMENTS
310
00:19:26,699 --> 00:19:29,167
DIRECTLY UNDER THE BODY.
311
00:19:29,169 --> 00:19:31,936
THE DRIVETRAIN IS THEN
RAISED INTO POSITION
312
00:19:31,938 --> 00:19:34,705
SO THE TWO SECTIONS
CAN BE SECURED WITH BOLTS.
313
00:20:12,378 --> 00:20:15,780
NOW, ANOTHER TEAM
INSTALLS THE HEADLIGHTS,
314
00:20:15,782 --> 00:20:18,649
WHEELS, TIRES, AND SEATS.
315
00:20:18,651 --> 00:20:23,287
THE FINAL STAGE CONSISTS OF AN
INSPECTION AND A STABILITY TEST.
316
00:20:39,405 --> 00:20:44,875
THEN IT'S OFF TO THE CUSTOMER
AND OUT ONTO THE OPEN ROAD.
317
00:20:44,877 --> 00:20:49,113
Meccia: THE LEGEND AND THE BRAND
IMAGE OF MASERATI BEGAN
318
00:20:49,115 --> 00:20:54,585
WITH THE WORLD OF RACES, SO MORE
THAN ONE CENTURY OF HISTORY.
319
00:20:54,587 --> 00:20:58,055
AND THIS IS WHY
MASERATI IS SO VALUABLE.
320
00:20:58,057 --> 00:21:01,192
Narrator: MASERATI IS OFTEN
REFERRED TO AS ONE OF THE TOP
321
00:21:01,194 --> 00:21:05,363
LUXURY CAR BRANDS IN HISTORY,
AND THE SKILL AND SOPHISTICATION
322
00:21:05,365 --> 00:21:07,832
FOUND INSIDE
THEIR PRODUCTION FACILITY
323
00:21:07,834 --> 00:21:12,703
MAKE IT ONE OF THE WORLD'S MOST
SPECTACULAR SUPER FACTORIES.
324
00:21:14,741 --> 00:21:19,377
COMING UP, IN JAPAN, CHARACTERS
FROM A BELOVED ANIME SERIES
325
00:21:19,379 --> 00:21:22,179
ARE BEING MANUFACTURED
FOR THE MASSES.
326
00:21:22,181 --> 00:21:25,283
THE KITS ARE BASED ON A 1970s
TV SERIES
327
00:21:25,285 --> 00:21:26,550
CALLED "GUNDAM."
328
00:21:26,552 --> 00:21:28,519
MODEL MAKERS AND
ANIME FANS IN JAPAN
329
00:21:28,521 --> 00:21:32,256
AND OTHER PARTS OF ASIA
ARE CRAZY ABOUT THEM.
330
00:21:32,258 --> 00:21:35,526
Narrator: AND LATER, THIS
FACTORY PRODUCES THE ALMIGHTY
331
00:21:35,528 --> 00:21:37,161
PORCELAIN THRONE
332
00:21:37,163 --> 00:21:39,964
USING A VERY UNIQUE MATERIAL.
333
00:21:39,966 --> 00:21:43,701
IT LOOKS LIKE CHOCOLATE,
BUT I WOULDN'T TASTE IT.
334
00:21:45,605 --> 00:21:55,212
¶¶
335
00:21:55,214 --> 00:22:00,685
Narrator:
IN TOKYO, THE WORLD'S LARGEST
HUMANOID ROBOT IS ON DISPLAY,
336
00:22:00,687 --> 00:22:02,887
MODELED AFTER
THE FICTIONAL ROBOTS
337
00:22:02,889 --> 00:22:06,457
FROM THE 1970s SCI-FI
FRANCHISE "GUNDAM,"
338
00:22:06,459 --> 00:22:09,694
THIS 65-FOOT-TALL REPLICA
HAS BECOME POPULAR
339
00:22:09,696 --> 00:22:12,963
WITH ANIME FANS
FROM AROUND THE GLOBE.
340
00:22:12,965 --> 00:22:15,199
BUT IT'S NOT JUST
THE GIANT ROBOT STATUE
341
00:22:15,201 --> 00:22:17,034
THAT'S DRAWING IN THE CROWDS.
342
00:22:17,036 --> 00:22:19,603
FOR A MORE INTERACTIVE
EXPERIENCE,
343
00:22:19,605 --> 00:22:21,972
FANS HEAD TO THE BANDAI
HOBBY CENTER
344
00:22:21,974 --> 00:22:23,908
AND MODELING SUPER FACTORY.
345
00:22:23,910 --> 00:22:26,243
SINCE 1980,
346
00:22:26,245 --> 00:22:30,247
THIS MANUFACTURING FACILITY
HAS COMBINED 3-D DESIGN,
347
00:22:30,249 --> 00:22:33,951
CUTTING EDGE TECHNOLOGY,
AND SKILLED CRAFTSMANSHIP
348
00:22:33,953 --> 00:22:36,620
TO PRODUCE GUNDAM
PLASTIC MODELING KITS.
349
00:22:36,622 --> 00:22:41,092
THE KITS ARE BASED ON A 1970s
TV SERIES CALLED "GUNDAM."
350
00:22:41,094 --> 00:22:43,260
MODEL MAKERS AND ANIME FANS
IN JAPAN
351
00:22:43,262 --> 00:22:46,130
AND OTHER PARTS OF ASIA
ARE CRAZY ABOUT THEM.
352
00:22:46,132 --> 00:22:49,900
BANDAI IS NOW THE SECOND BIGGEST
TOY COMPANY IN THE WORLD,
353
00:22:49,902 --> 00:22:53,304
VALUED AT $9.6 BILLION.
354
00:22:55,341 --> 00:22:58,542
Narrator: GUNDAM TOYS ARE
CONSTRUCTED FROM PLASTIC FRAMES
355
00:22:58,544 --> 00:23:02,913
THAT CONTAIN INDIVIDUAL PIECES
CALLED RUNNERS,
356
00:23:02,915 --> 00:23:05,182
THE INDIVIDUAL PIECES
ARE ALL NUMBERED,
357
00:23:05,184 --> 00:23:08,219
SO THE MODEL KITS
CAN BE EASILY ASSEMBLED.
358
00:23:10,723 --> 00:23:14,091
THE FIRST STEP
IS DESIGNING A CHARACTER.
359
00:23:14,093 --> 00:23:17,061
TODAY, IT'S
THE GUNDAM RED FLAME.
360
00:23:17,063 --> 00:23:22,233
¶¶
361
00:23:22,235 --> 00:23:25,603
THE DESIGN IS BROKEN DOWN
INTO INDIVIDUAL PARTS
362
00:23:25,605 --> 00:23:27,471
THAT MAKE UP THE MODEL KITS.
363
00:23:47,493 --> 00:23:50,327
BANDAI USES 3-D PRINTING
TO CREATE MODELS
364
00:23:50,329 --> 00:23:53,798
FOR OVER 400 DIFFERENT DESIGNS.
365
00:23:53,800 --> 00:23:56,867
THIS STATE-OF-THE-ART TECHNOLOGY
366
00:23:56,869 --> 00:24:00,237
HAS COMPLETELY TRANSFORMED
THE TOY INDUSTRY.
367
00:24:00,239 --> 00:24:02,606
3-D PRINTING, MORE COMMONLY
TODAY KNOWN AS
368
00:24:02,608 --> 00:24:04,108
ADDITIVE MANUFACTURING,
369
00:24:04,110 --> 00:24:06,277
ACTUALLY BEGAN IN 1986.
370
00:24:06,279 --> 00:24:08,179
THE FIRST PRODUCT TO BE PRINTED
371
00:24:08,181 --> 00:24:12,550
WAS A SMALL PLASTIC CUP
USED FOR HOLDING EYEWASH.
372
00:24:12,552 --> 00:24:14,985
TODAY, 3-D PRINTERS
USE A RANGE OF MATERIALS
373
00:24:14,987 --> 00:24:18,189
TO PRODUCE THEIR PRODUCTS,
FROM RESINS AND PLASTICS
374
00:24:18,191 --> 00:24:21,258
TO CERAMICS
AND EVEN ADVANCED METALS.
375
00:24:21,260 --> 00:24:23,427
THE HUGE ADVANTAGE
IN 3-D PRINTING
376
00:24:23,429 --> 00:24:25,229
FOR INVENTORS
AND ENGINEERS
377
00:24:25,231 --> 00:24:28,065
IS THEY CAN MAKE A ONE-OFF,
A SINGLE PRODUCT
378
00:24:28,067 --> 00:24:30,701
THAT WORKS WITHOUT
THE VAST CAPITAL EQUIPMENT
379
00:24:30,703 --> 00:24:34,772
INVESTMENTS OF
A WHOLE PRODUCTION LINE.
380
00:24:34,774 --> 00:24:37,374
Narrator: NEXT, TECHNICIANS
CONFIGURE THE LAYOUT
381
00:24:37,376 --> 00:24:41,045
FOR THE MOLDS BY ARRANGING
THE PARTS INTO KITS.
382
00:24:43,149 --> 00:24:47,585
ONCE THE LAYOUT IS FINALIZED
AND THE 3-D DATA IS COMPLETED,
383
00:24:47,587 --> 00:24:50,221
THE DESIGN IS SENT
TO THE MOLDING TEAM.
384
00:24:52,291 --> 00:24:53,891
THROUGH A FABRICATION PROCESS
385
00:24:53,893 --> 00:24:56,961
CALLED ELECTRICAL
DISCHARGE MACHINING,
386
00:24:56,963 --> 00:24:59,363
A LASER CUTS
THROUGH A METAL BLOCK,
387
00:24:59,365 --> 00:25:02,900
FORMING IT INTO VARIOUS SHAPES.
388
00:25:02,902 --> 00:25:05,436
ELECTRICAL DISCHARGE MACHINING
IS A WAY OF CUTTING METAL
389
00:25:05,438 --> 00:25:07,037
USING ELECTRICITY.
390
00:25:07,039 --> 00:25:09,607
MATERIAL IS REMOVED
FROM A METAL BLOCK
391
00:25:09,609 --> 00:25:13,444
BY A SERIES OF RAPIDLY
RECURRING CURRENT DISCHARGES.
392
00:25:13,446 --> 00:25:15,546
THE TWO CONDUCTORS
ARE SEPARATED BY A LIQUID
393
00:25:15,548 --> 00:25:18,449
AND THE RESULTING SPARKS
ERODE THE METAL,
394
00:25:18,451 --> 00:25:20,684
A BIT LIKE CREATING
MINI LIGHTNING BOLTS
395
00:25:20,686 --> 00:25:25,422
THAT CREATE INTENSE HEAT WHICH
FORM THE DESIRED FINAL SHAPE.
396
00:25:27,827 --> 00:25:31,495
Narrator: NOW THE CONCAVE
AND CONVEX METAL SHAPES
397
00:25:31,497 --> 00:25:35,566
ARE CARVED OUT OF THE SOLID
BLOCK, THEN TRIMMED.
398
00:25:35,568 --> 00:25:39,270
THIS STEP CAN ONLY
BE DONE BY HAND.
399
00:25:39,272 --> 00:25:43,407
TECHNICIANS TRIM THE CORNERS
AND MAKE GROOVES.
400
00:25:43,409 --> 00:25:44,875
THE METAL SHAPES ARE CONFIGURED
401
00:25:44,877 --> 00:25:48,078
INTO WHAT WILL BECOME
A PLASTIC FRAME.
402
00:25:48,080 --> 00:25:50,714
IF ANY MISTAKE OCCURS
DURING SHAPING,
403
00:25:50,716 --> 00:25:53,317
THE ENTIRE MOLD
HAS TO BE THROWN OUT.
404
00:26:23,482 --> 00:26:27,985
A CRANE TRANSPORTS THE MOLDS
TO AN INJECTION MOLDING MACHINE.
405
00:26:27,987 --> 00:26:31,789
HERE, THE MOLDS ARE LOADED
AND CLAMPED WITH ENOUGH FORCE
406
00:26:31,791 --> 00:26:34,058
TO KEEP THEM SECURELY IN PLACE.
407
00:26:36,929 --> 00:26:41,599
THEN POLYSTYRENE PELLETS,
A RAW PLASTIC MATERIAL,
408
00:26:41,601 --> 00:26:44,468
IS FED INTO THE MACHINE
THROUGH A NETWORK OF TUBES.
409
00:26:45,905 --> 00:26:48,339
PLASTICS, AS WE KNOW
AND EXPERIENCE THEM TODAY,
410
00:26:48,341 --> 00:26:51,542
ARE PRIMARILY DERIVED FROM
NATURALLY OCCURRING MATERIALS
411
00:26:51,544 --> 00:26:54,478
SUCH AS OIL AND PLANT STARCHES.
412
00:26:54,480 --> 00:26:58,048
BUT ACTUALLY, EARLY PLASTICS
WERE DERIVED FROM CELLULOSE,
413
00:26:58,050 --> 00:27:01,085
DIRECTLY TAKEN
FROM PLANT FIBERS.
414
00:27:01,087 --> 00:27:04,121
Narrator: ONCE THE PELLETS ARE
INJECTED INTO THE MACHINE,
415
00:27:04,123 --> 00:27:07,257
THEY'RE MELTED AND PRESSURIZED.
416
00:27:07,259 --> 00:27:11,128
PLASTIC IS INJECTED
INTO THE MOLD VERY QUICKLY.
417
00:27:11,130 --> 00:27:15,065
THE BUILDUP OF PRESSURE PACKS
AND HOLDS THE MATERIAL TOGETHER.
418
00:27:25,878 --> 00:27:29,213
INJECTION MOLDING MAY SEEM
LIKE A 21st CENTURY
419
00:27:29,215 --> 00:27:30,748
MANUFACTURING TECHNIQUE,
420
00:27:30,750 --> 00:27:33,751
BUT THE PROCESS HAS
A LONG HISTORY.
421
00:27:33,753 --> 00:27:36,453
A VERY SIMPLE VERSION
OF INJECTION MOLDING
422
00:27:36,455 --> 00:27:40,157
WAS ATTEMPTED
AS FAR BACK AS 1872
423
00:27:40,159 --> 00:27:42,092
TO PRODUCE BILLIARD BALLS.
424
00:27:42,094 --> 00:27:44,695
BUT IT REALLY TOOK OFF
AFTER WORLD WAR II
425
00:27:44,697 --> 00:27:48,866
WHEN THERE WAS A HUGE DEMAND FOR
CHEAP, MASS-PRODUCED PRODUCTS.
426
00:27:48,868 --> 00:27:52,936
INVENTOR JAMES HENDRY
DESIGNED A MACHINE
427
00:27:52,938 --> 00:27:56,507
THAT USED A TURNING HEATED SCREW
428
00:27:56,509 --> 00:28:00,878
BOTH TO MELT THE PLASTIC
AND TO INJECT THE MOLD.
429
00:28:00,880 --> 00:28:04,415
IT REALLY WAS GROUNDBREAKING
BECAUSE TODAY THIS DESIGN
430
00:28:04,417 --> 00:28:09,286
MAKES UP 95% OF ALL
INJECTION MOLDING MACHINES.
431
00:28:09,288 --> 00:28:14,858
¶¶
432
00:28:14,860 --> 00:28:17,361
Narrator: THE MOLTEN PLASTIC
BEGINS TO COOL
433
00:28:17,363 --> 00:28:18,729
AS SOON AS IT MAKES CONTACT
434
00:28:18,731 --> 00:28:20,597
WITH THE INTERIOR OF THE MOLD.
435
00:28:20,599 --> 00:28:22,733
AS THE PLASTIC COOLS,
436
00:28:22,735 --> 00:28:25,035
IT SOLIDIFIES INTO SHAPE.
437
00:28:27,773 --> 00:28:30,340
TO GUARANTEE EFFICIENCY,
438
00:28:30,342 --> 00:28:35,112
BANDAI UTILIZES THEIR SIGNATURE
COOLING PROCESS.
439
00:28:35,114 --> 00:28:37,414
IN ORDER TO SPEED UP
THE MANUFACTURING PROCESS,
440
00:28:37,416 --> 00:28:40,250
THE MOLDS ARE CHILLED SO
THAT WHEN THE HOT PLASTIC
441
00:28:40,252 --> 00:28:41,885
HITS THE SURFACE OF THE MOLD,
442
00:28:41,887 --> 00:28:45,956
IT COOLS DOWN MORE QUICKLY
AND THE OBJECT SETS FASTER.
443
00:28:45,958 --> 00:28:51,195
Narrator: THIS PROCESS INCREASES
COOLING PRODUCTIVITY BY 20%.
444
00:28:51,197 --> 00:28:52,963
DOWN THE ASSEMBLY LINE,
445
00:28:52,965 --> 00:28:56,333
INJECTION MOLDING MACHINES
OPERATE AROUND THE CLOCK.
446
00:29:23,929 --> 00:29:27,631
NEXT, AUTOMATIC GUIDED VEHICLES
TRANSPORT THE BOXES
447
00:29:27,633 --> 00:29:30,367
TO A WAREHOUSE
WHERE THEY'RE STORED
448
00:29:30,369 --> 00:29:32,569
UNTIL THEY'RE READY
TO BE DISPATCHED.
449
00:29:36,375 --> 00:29:39,576
THE MODELS ARE SHIPPED
TO STORES AROUND THE WORLD,
450
00:29:39,578 --> 00:29:44,648
BUT NOWHERE ARE THEY MORE
POPULAR THAN HERE IN JAPAN.
451
00:29:44,650 --> 00:29:48,552
IN ITS TOKYO SHOP,
BANDAI GIVES GUNDAM ENTHUSIASTS
452
00:29:48,554 --> 00:29:50,754
A HANDS-ON EXPERIENCE
453
00:29:50,756 --> 00:29:54,391
ASSEMBLING SOME OF THEIR
FAVORITE ANIME CHARACTERS.
454
00:29:54,393 --> 00:29:57,327
IN THE PROFITABLE BUSINESS
OF MODEL MAKING,
455
00:29:57,329 --> 00:30:00,964
THESE TOY ROBOTS ARE SURE
TO DOMINATE THE MARKET
456
00:30:00,966 --> 00:30:04,067
FOR LIGHT YEARS TO COME.
457
00:30:04,069 --> 00:30:07,337
AND IT'S ALL THANKS
TO THE INDUSTRIAL INFRASTRUCTURE
458
00:30:07,339 --> 00:30:09,339
AND PRECISION
CRAFTSMANSHIP
459
00:30:09,341 --> 00:30:12,643
FOUND IN THE BANDAI
SUPER FACTORY.
460
00:30:14,713 --> 00:30:17,781
COMING UP,
A EUROPEAN MANUFACTURER
461
00:30:17,783 --> 00:30:20,484
IS FLUSHING OUT THE COMPETITION
462
00:30:20,486 --> 00:30:24,388
BY PUSHING THE BOUNDARIES
OF DESIGN AND ENGINEERING.
463
00:30:27,293 --> 00:30:36,266
¶¶
464
00:30:36,268 --> 00:30:38,569
Narrator: LOCATED IN
STAFFORDSHIRE, ENGLAND,
465
00:30:38,571 --> 00:30:40,737
IS THE ARMITAGE SHANK'S
BATH APPLIANCE
466
00:30:40,739 --> 00:30:44,308
AND MANUFACTURING FACILITY.
467
00:30:44,310 --> 00:30:48,011
SINCE 1851, THIS FACTORY
HAS BEEN PRODUCING
468
00:30:48,013 --> 00:30:51,248
A WIDE VARIETY OF SANITARY
WARE APPLIANCES,
469
00:30:51,250 --> 00:30:57,654
INCLUDING THEIR MOST RENOWNED
PRODUCT -- TOILETS.
470
00:30:57,656 --> 00:31:00,390
AND WHAT MAKES
THESE TOILETS UNIQUE?
471
00:31:00,392 --> 00:31:04,394
THE MATERIALS THEY'RE MADE WITH.
472
00:31:04,396 --> 00:31:06,330
THE PROCESS STARTS
WITH A DELIVERY
473
00:31:06,332 --> 00:31:11,301
OF MORE THAN 165,000 POUNDS
OF IMPORTED CLAY.
474
00:31:11,303 --> 00:31:17,441
¶¶
475
00:31:17,443 --> 00:31:19,042
SO, YEAH, SO THIS
IS A CHINA CLAY
476
00:31:19,044 --> 00:31:20,477
THAT'S COME IN THIS MORNING.
477
00:31:20,479 --> 00:31:24,514
THIS IS MINED IN CORNWALL.
478
00:31:24,516 --> 00:31:28,418
SO WE'VE GOT TWO TYPES OF CLAY
HERE, CHINA CLAY AND BALL CLAY.
479
00:31:28,420 --> 00:31:31,255
THE BALL CLAY GIVES US
THE STRENGTH AND VISCOSITY.
480
00:31:31,257 --> 00:31:33,223
AND THEN WE'VE GOT
THE CHINA CLAY.
481
00:31:33,225 --> 00:31:36,994
IT'S A BIT MORE CRUMBLY BECAUSE
OF THE SET CASTING TIMES.
482
00:31:36,996 --> 00:31:39,897
KAOLIN OR CHINA CLAY, AS IT'S
MORE COMMONLY KNOWN,
483
00:31:39,899 --> 00:31:42,599
IS A RARE FORM
OF DECOMPOSED GRANITE
484
00:31:42,601 --> 00:31:45,836
THAT HAS A SUPERFINE
POWDERY TEXTURE.
485
00:31:45,838 --> 00:31:47,537
ONCE YOU MIX IT
WITH BALL CLAY
486
00:31:47,539 --> 00:31:49,640
TO ADD STRENGTH AND PLASTICITY,
487
00:31:49,642 --> 00:31:51,575
IT'S THEN READY TO BE WORKED
AND SHAPED
488
00:31:51,577 --> 00:31:54,745
AND CAN BE MOLDED INTO FINE
CHINA OR TABLEWARE
489
00:31:54,747 --> 00:31:57,281
OR EVEN TOILETS.
490
00:31:57,283 --> 00:32:01,885
Narrator:
TURNING CLAY INTO PORCELAIN
STARTS IN THE MIXING BAY.
491
00:32:01,887 --> 00:32:05,555
TWO DIFFERENT TYPES OF CLAY,
SAND, AND A FEW CHEMICALS
492
00:32:05,557 --> 00:32:07,891
ARE MIXED TOGETHER WITH WATER.
493
00:32:10,696 --> 00:32:14,264
IT'S ALL MIXED TOGETHER
IN THESE 6,000 LITER TANKS
494
00:32:14,266 --> 00:32:15,632
WITH ALL THESE BLUNGERS.
495
00:32:15,634 --> 00:32:17,634
IT'S BASICALLY
A GIANT CAKE MIXER
496
00:32:17,636 --> 00:32:21,371
MIXING ALL THE INGREDIENTS
TOGETHER TO MAKE LIQUID CLAY,
497
00:32:21,373 --> 00:32:24,007
WHICH IS KNOWN AS SLIP
IN THE INDUSTRY.
498
00:32:24,009 --> 00:32:28,078
Narrator: IN EACH MIXING
VAT OR BLUNGER, WATER AND CLAY
499
00:32:28,080 --> 00:32:30,914
ARE MIXED TOGETHER
FOR 70 MINUTES.
500
00:32:30,916 --> 00:32:32,616
ONCE MIXING IS COMPLETE,
501
00:32:32,618 --> 00:32:37,621
THE LIQUID CLAY IS DISPENSED
THROUGH A GIANT FILTER OR SIEVE.
502
00:32:37,623 --> 00:32:41,858
THIS PROCESS REMOVES
ANY IMPURITIES.
503
00:32:41,860 --> 00:32:44,561
THE MACHINES IS BASICALLY
A VIBRATING TANK,
504
00:32:44,563 --> 00:32:49,199
IT'S FITTED WITH ONE
OF THESE MEMBRANES.
505
00:32:49,201 --> 00:32:51,368
AND IT SIFTS THROUGH THERE.
506
00:32:51,370 --> 00:32:52,669
YEAH, I MEAN, THIS
IS THE KIND OF STUFF
507
00:32:52,671 --> 00:32:54,237
WE MIGHT GET OUT OF THERE.
508
00:32:54,239 --> 00:32:56,773
SOME COARSE MATERIAL,
SOME STONES.
509
00:32:56,775 --> 00:32:58,742
WE DON'T WANT THAT
IN THE FINAL PRODUCT.
510
00:32:58,744 --> 00:33:01,378
Narrator: ONCE THE UNWANTED
MATERIAL IS SEPARATED,
511
00:33:01,380 --> 00:33:04,414
THE CLAY IS TURNED INTO
A SMOOTH PASTE.
512
00:33:04,416 --> 00:33:08,919
IT LOOKS LIKE CHOCOLATE,
BUT I WOULDN'T TASTE IT.
513
00:33:08,921 --> 00:33:12,356
Narrator: NEXT, THE LIQUID CLAY
IS PUMPED AND DISTRIBUTED
514
00:33:12,358 --> 00:33:15,525
INTO A 265-GALLON HOLDING TANK,
515
00:33:15,527 --> 00:33:18,996
WHERE IT'S MIXED
AT A CONSTANT TEMPERATURE.
516
00:33:18,998 --> 00:33:21,231
SO IT'S BEEN MIXED
QUITE AGGRESSIVELY.
517
00:33:21,233 --> 00:33:22,699
A LOT OF ENERGY
HAS GONE INTO IT.
518
00:33:22,701 --> 00:33:25,268
WE NOW NEED IT TO CALM DOWN,
JUST SETTLE DOWN.
519
00:33:25,270 --> 00:33:27,904
IT'S BASICALLY
AN AGING PROCESS.
520
00:33:27,906 --> 00:33:31,408
Narrator: TRADITIONAL TOILETS
DATE BACK TO 1596,
521
00:33:31,410 --> 00:33:34,578
WHEN SIR JOHN HARRINGTON,
AN ENGLISH COURTIER
522
00:33:34,580 --> 00:33:37,347
AND THE GODSON OF
QUEEN ELIZABETH I,
523
00:33:37,349 --> 00:33:41,184
DESIGNED THE FIRST
FLUSHABLE TOILET.
524
00:33:41,186 --> 00:33:44,821
HIS DEVICE USED A 24-INCH
DEEP OVAL BOWL
525
00:33:44,823 --> 00:33:46,890
FED BY WATER
FROM A RESERVOIR.
526
00:33:46,892 --> 00:33:48,892
FLUSHING HARRINGTON'S TOILET
527
00:33:48,894 --> 00:33:51,828
REQUIRED NEARLY EIGHT GALLONS
OF WATER,
528
00:33:51,830 --> 00:33:54,998
WHILE TODAY'S TOILETS
USE LESS THAN ONE GALLON.
529
00:33:55,000 --> 00:33:58,402
THE PROBLEM WITH THE DESIGN
IS THAT THE BOWL WASHED
530
00:33:58,404 --> 00:34:00,971
STRAIGHT INTO A CESSPOOL BELOW,
531
00:34:00,973 --> 00:34:04,741
SO THE STENCH OUTWEIGHED
THE CONTRAPTION'S CONVENIENCE.
532
00:34:04,743 --> 00:34:08,278
HARRINGTON PROVED
THAT A TOILET WITHOUT A SEWER
533
00:34:08,280 --> 00:34:11,114
IS JUST A GIGANTIC CHAMBER POT.
534
00:34:11,116 --> 00:34:14,217
HIS NOVEL IDEA
WENT DOWN THE DRAIN.
535
00:34:14,219 --> 00:34:17,654
[ FLUSHING ]
536
00:34:17,656 --> 00:34:19,189
Narrator:
AND IN THIS FACTORY,
537
00:34:19,191 --> 00:34:23,293
ARMITAGE SHANKS HAS IMPLEMENTED
ANOTHER INNOVATIVE CONCEPT
538
00:34:23,295 --> 00:34:26,830
THAT DRASTICALLY CUTS DOWN
ON PRODUCTION TIME.
539
00:34:29,735 --> 00:34:35,072
¶¶
540
00:34:35,074 --> 00:34:38,275
Narrator: FOR MORE THAN
200 YEARS, ARMITAGE SHANKS
541
00:34:38,277 --> 00:34:41,778
HAS BEEN PUSHING THE BOUNDARIES
OF DESIGN AND INNOVATION
542
00:34:41,780 --> 00:34:45,549
TO MANUFACTURE CERAMIC
SANITARY WARE PRODUCTS.
543
00:34:45,551 --> 00:34:47,784
TODAY AT THIS PRODUCTION
FACILITY,
544
00:34:47,786 --> 00:34:49,786
THE USE OF MODERN MATERIALS
545
00:34:49,788 --> 00:34:52,055
IS COMBINED WITH
THE LATEST TECHNOLOGY
546
00:34:52,057 --> 00:34:56,026
TO PRODUCE MORE
THAN 1,500 TOILETS A DAY.
547
00:34:56,028 --> 00:34:59,262
BACK ON THE PRODUCTION LINE,
THE LIQUID CLAY IS READY TO BE
548
00:34:59,264 --> 00:35:02,566
TRANSFORMED INTO
THE FAMILIAR TOILET SHAPE.
549
00:35:04,837 --> 00:35:07,104
TRADITIONALLY,
THE CASTING PROCESS
550
00:35:07,106 --> 00:35:09,873
REQUIRED THE MATERIAL
TO BE POURED BY HAND,
551
00:35:09,875 --> 00:35:11,875
BUT THANKS TO MODERN TECHNOLOGY,
552
00:35:11,877 --> 00:35:15,378
AN INJECTION MOLDING MACHINE
PERFORMS THE TASK.
553
00:35:15,380 --> 00:35:18,081
PREVIOUSLY IT WAS PLASTER MOLDS.
554
00:35:18,083 --> 00:35:19,716
SO WE HAD A BIG ROW
OF PLASTER MOLDS
555
00:35:19,718 --> 00:35:22,385
THAT PERHAPS LASTED
TWO TO THREE WEEKS
556
00:35:22,387 --> 00:35:23,820
THAT HAD TO BE REPLACED.
557
00:35:23,822 --> 00:35:25,822
WE HAD TO HAVE A
MOLD-MAKING DEPARTMENT
558
00:35:25,824 --> 00:35:27,491
CONTINUOUSLY MAKING
PLASTER MOLDS.
559
00:35:27,493 --> 00:35:29,025
THE THING WITH THE OLD WAY.
560
00:35:29,027 --> 00:35:31,828
IT WAS THE WASTE AND THE MAN
HOURS AND MATERIALS
561
00:35:31,830 --> 00:35:33,897
THAT USED TO HAVE TO GO
INTO THE PLASTER MOLDS.
562
00:35:33,899 --> 00:35:36,600
THESE REUSABLE MOLDS
THAT ARE POROUS RESIN,
563
00:35:36,602 --> 00:35:39,736
WE GET 20,000 TO 30,000
CYCLES OUT OF EACH ONE.
564
00:35:39,738 --> 00:35:43,240
THE USE OF MODERN MATERIALS HAS
TRANSFORMED THE PRODUCTION LINE,
565
00:35:43,242 --> 00:35:46,576
IT ENABLES IT TO WORK
CONTINUOUSLY 24 HOURS A DAY.
566
00:35:46,578 --> 00:35:50,080
THERE'S NO STOPPING TO REPAIR
BROKEN CASTS OR MOLDS.
567
00:35:53,118 --> 00:35:56,019
Narrator: WHEN THE TOILET FIRST
COMES OUT OF THE MOLD,
568
00:35:56,021 --> 00:35:59,923
IT'S SOFT AND ALMOST JELLYLIKE.
569
00:35:59,925 --> 00:36:04,794
A TECHNICIAN USES SPONGES
AND KNIVES TO SMOOTH DOWN SEAMS,
570
00:36:04,796 --> 00:36:09,566
SHAPE THE RIM, AND CHECK
FOR ANY IMPERFECTIONS.
571
00:36:09,568 --> 00:36:15,205
THIS WORK IS SO PRECISE
IT MUST BE DONE BY HAND.
572
00:36:15,207 --> 00:36:19,709
ANY TOILET NOT UP
TO SNUFF IS RECYCLED.
573
00:36:19,711 --> 00:36:22,145
ONCE THE TOILETS
ARE SHAPED TO PERFECTION,
574
00:36:22,147 --> 00:36:24,247
THEY'RE TRANSPORTED
DOWN THE ASSEMBLY LINE
575
00:36:24,249 --> 00:36:26,116
TO THE DRYING TUNNEL.
576
00:36:26,118 --> 00:36:29,586
THE TOILETS GO INTO
THE 195 DEGREE DRYERS
577
00:36:29,588 --> 00:36:31,421
FOR EIGHT TO 10 HOURS.
578
00:36:31,423 --> 00:36:33,023
TO DRY THIS WARE OUT NATURALLY,
579
00:36:33,025 --> 00:36:35,058
YOU'RE LOOKING AT
TWO TO THREE DAYS.
580
00:36:35,060 --> 00:36:38,361
SO THIS TUNNEL DRYER IS AN
ESSENTIAL PART OF THE PROCESS.
581
00:36:41,300 --> 00:36:44,167
Narrator: SINCE THE DRYING
PROCESS REMOVES MOISTURE,
582
00:36:44,169 --> 00:36:47,971
THE SIZE OF THE TOILET
SHRINKS BY 2.5%.
583
00:36:51,310 --> 00:36:56,379
NEXT, EACH TOILET IS INSPECTED
FOR ANY REMAINING IMPERFECTIONS,
584
00:36:56,381 --> 00:36:59,416
THEN A TECHNICIAN
BLENDS IN THE SEAMS,
585
00:36:59,418 --> 00:37:01,618
REMOVES ANY ROUGH EDGES,
586
00:37:01,620 --> 00:37:06,423
AND MAKES ONE FINAL
VISUAL INSPECTION.
587
00:37:06,425 --> 00:37:10,594
NOW THE TOILETS ARE READY
FOR GLAZING.
588
00:37:10,596 --> 00:37:12,629
ONCE THE GLAZE IS ON THE PIECE,
THERE'S NO GOING BACK.
589
00:37:12,631 --> 00:37:16,833
IT NEEDS TO BE PRISTINE.
IT NEEDS TO BE PERFECT.
590
00:37:16,835 --> 00:37:20,670
Narrator: A ROBOTIC ARM SPRAYS
FOUR LAYERS OF LIQUID GLAZE
591
00:37:20,672 --> 00:37:24,107
CONTAINING ALUMINUM OXIDE
AND SILICA SAND.
592
00:37:27,646 --> 00:37:30,680
IT MAY SOUND OBVIOUS, BUT A
TOILET NEEDS TO BE WATERPROOF.
593
00:37:30,682 --> 00:37:32,916
AND IF YOU JUST HAD PORCELAIN
AND FIRED IT,
594
00:37:32,918 --> 00:37:36,219
YOU'D HAVE A SURFACE
WHICH WAS SLIGHTLY POROUS.
595
00:37:36,221 --> 00:37:38,421
SO YOU NEED TO GLAZE
THAT PORCELAIN.
596
00:37:38,423 --> 00:37:41,324
AND ONCE GLAZED,
THE LOO ACTUALLY BECOMES
597
00:37:41,326 --> 00:37:45,729
THE CLEAN, HYGIENIC OBJECT
WE ALL KNOW AND LOVE.
598
00:37:45,731 --> 00:37:47,897
Narrator:
AS A LEADER IN THE INDUSTRY,
599
00:37:47,899 --> 00:37:49,866
ARMITAGE SHANKS HAS COME
A LONG WAY
600
00:37:49,868 --> 00:37:51,868
SINCE THE COMPANY
WAS FIRST FOUNDED
601
00:37:51,870 --> 00:37:55,005
MORE THAN 200 YEARS AGO.
602
00:37:55,007 --> 00:37:57,040
IN THE LATE 1960s,
603
00:37:57,042 --> 00:38:00,043
THE COMPANY CREATED
AN AVOCADO BATH LINE,
604
00:38:00,045 --> 00:38:02,279
WHICH BECAME VERY POPULAR
IN COMMERCIAL
605
00:38:02,281 --> 00:38:06,015
AND RESIDENTIAL HOUSEHOLDS
AROUND THE WORLD.
606
00:38:06,017 --> 00:38:08,685
HOWEVER,
THE RETRO BATHROOM SUITE
607
00:38:08,687 --> 00:38:10,553
DIDN'T STAND THE TEST OF TIME
608
00:38:10,555 --> 00:38:14,057
AND FIZZLED OUT OF PRODUCTION
BY THE LATE 1980s.
609
00:38:14,059 --> 00:38:17,794
WE CAN DO ANY COLOR YOU WANT,
AS LONG AS IT'S WHITE.
610
00:38:17,796 --> 00:38:19,996
Narrator: FOUNDED IN 1817,
611
00:38:19,998 --> 00:38:22,132
THE COMPANY EMERGED
DURING A TIME
612
00:38:22,134 --> 00:38:25,502
WHEN THE LACK OF SANITATION
WAS SO BAD IN THE U.K.
613
00:38:25,504 --> 00:38:29,506
THAT LIFE EXPECTANCY
WAS ONLY 40 YEARS.
614
00:38:29,508 --> 00:38:32,609
FLUSHING TECHNOLOGY WAS IMPROVED
THROUGH THE EFFORTS
615
00:38:32,611 --> 00:38:34,444
OF ALEXANDER CUMMINGS,
616
00:38:34,446 --> 00:38:39,749
WHO INVENTED THE S-BEND PIPE,
AND LATER, THOMAS CRAPPER,
617
00:38:39,751 --> 00:38:43,753
WHO IMPROVED UPON CUMMINGS
DESIGN, INVENTING THE U-BEND.
618
00:38:43,755 --> 00:38:47,390
THE DIRECT PIPE THAT CONNECTED
THE TOILET WITH A SEWER
619
00:38:47,392 --> 00:38:49,359
WOULD FLUSH THE WASTE AWAY,
620
00:38:49,361 --> 00:38:52,762
BUT UNFORTUNATELY IT WOULD ALSO
LET SEWER ODORS
621
00:38:52,764 --> 00:38:54,331
PERCOLATE BACK UP,
622
00:38:54,333 --> 00:38:57,667
SO AN AIRTIGHT SEAL
HAD TO BE CREATED.
623
00:38:57,669 --> 00:39:00,704
HE MADE A U-BEND IN THE PIPE.
624
00:39:00,706 --> 00:39:03,206
WATER SETTLES AT THE BOTTOM
OF THE "U,"
625
00:39:03,208 --> 00:39:06,776
MAKING A SEAL AND STOPPING
THE SMELLS FROM COMING BACK UP.
626
00:39:06,778 --> 00:39:08,345
WHEN THE TOILET IS FLUSHED
AGAIN,
627
00:39:08,347 --> 00:39:12,248
THE WATER IS REPLENISHED
AND THE SEAL REMADE.
628
00:39:12,250 --> 00:39:15,385
Narrator: THANKS TO THE
INGENUITY OF THEIR ENGINEERS,
629
00:39:15,387 --> 00:39:18,822
ARMITAGE SHANKS WAS THE FIRST
BUSINESS TO CONNECT TOILETS
630
00:39:18,824 --> 00:39:20,557
TO SEWER SYSTEMS,
631
00:39:20,559 --> 00:39:24,694
RAPIDLY IMPROVING
PUBLIC SANITATION.
632
00:39:24,696 --> 00:39:26,396
BACK ON THE ASSEMBLY LINE,
633
00:39:26,398 --> 00:39:29,666
THE GLAZED TOILETS
ARE READY FOR FIRING.
634
00:39:29,668 --> 00:39:33,069
FIRING IS THE PROCESS
OF TURNING CLAY AND GLAZE
635
00:39:33,071 --> 00:39:37,474
INTO LONG-LASTING WATERPROOF
PORCELAIN USING EXTREME HEAT.
636
00:39:37,476 --> 00:39:40,009
THE TOILETS ARE PLACED
ON A FIREPROOF PALLET
637
00:39:40,011 --> 00:39:44,214
AND HEATED AT 2,192 DEGREES.
638
00:39:44,216 --> 00:39:48,051
Spink: THE FIRING PROCESS ITSELF
CAUSES A CHEMICAL REACTION.
639
00:39:48,053 --> 00:39:53,356
THIS CHEMICAL REACTION FUSES THE
BODY OF THE CLAY TO THE GLAZE.
640
00:39:53,358 --> 00:39:55,792
Narrator:
AFTER 16 HOURS IN THE KILN,
641
00:39:55,794 --> 00:39:59,295
THE PORCELAIN IS FINALLY
SOLIDIFIED.
642
00:39:59,297 --> 00:40:02,332
THE TOILETS ARE COOLED
FOR EIGHT HOURS.
643
00:40:02,334 --> 00:40:05,168
THEN THEY'RE CHECKED FOR CRACKS.
644
00:40:08,106 --> 00:40:10,940
AND NOW 50 HOURS LATER,
HERE WE HAVE IT,
645
00:40:10,942 --> 00:40:14,210
A BEAUTIFUL TOILET READY
FOR A LIFETIME OF SERVICE.
646
00:40:14,212 --> 00:40:15,512
IT'S ONE OF THOSE BRAND NAMES
647
00:40:15,514 --> 00:40:18,047
THAT JUST GETS INSIDE
OF YOUR HEAD.
648
00:40:18,049 --> 00:40:22,519
WHY? BECAUSE YOU HAVE TIME
TO CONTEMPLATE IT ALONE.
649
00:40:22,521 --> 00:40:25,321
ARMITAGE SHANKS HAS BEEN
A CHARACTER IN A MOVIE
650
00:40:25,323 --> 00:40:27,257
AND IN A VIDEO GAME,
651
00:40:27,259 --> 00:40:30,927
PLUS THE INSPIRATION
FOR SIX POP SONGS,
652
00:40:30,929 --> 00:40:34,230
AND THE TITLE
OF A BRITISH PUNK-ROCK BAND.
653
00:40:37,269 --> 00:40:39,903
Narrator: OVER TIME,
ARMITAGE SHANKS HAS RISEN
654
00:40:39,905 --> 00:40:43,440
TO THE TOP OF THE INDUSTRY.
655
00:40:43,442 --> 00:40:47,310
TODAY, THE COMPANY CONTINUES
TO REVOLUTIONIZE THE BRAND
656
00:40:47,312 --> 00:40:50,213
THROUGH THEIR USE
OF MODERN MATERIALS
657
00:40:50,215 --> 00:40:53,516
AND BY IMPLEMENTING THE LATEST
MANUFACTURING OPERATIONS
658
00:40:53,518 --> 00:40:57,020
AND TECHNOLOGIES
ON THEIR ASSEMBLY LINES.
659
00:40:57,022 --> 00:40:59,055
ALL THESE ELEMENTS COMBINED
660
00:40:59,057 --> 00:41:02,926
MAKE THIS FACTORY
A SUPER FACTORY.
661
00:41:02,928 --> 00:41:04,360
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