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00:00:01,902 --> 00:00:04,837
Narrator: This super-sized
sorting distribution hub
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00:00:04,839 --> 00:00:07,573
Comes with its very own airport.
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The secrets of this
instantly satisfying
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00:00:12,980 --> 00:00:15,981
Korean noodle soup
are revealed.
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00:00:18,719 --> 00:00:21,687
Bikes are being transformed
to meet the needs
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00:00:21,689 --> 00:00:24,289
Of city dwellers
and commuters alike.
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00:00:26,360 --> 00:00:29,528
And a digitized facility
where high tech
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00:00:29,530 --> 00:00:34,033
Doesn't have to mean
fewer workers.
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These groundbreaking innovations
are all taking place
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00:00:37,538 --> 00:00:40,839
Inside some of the most
incredible factories
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00:00:40,841 --> 00:00:42,574
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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♪♪
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When it comes to
transporting cargo by air,
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Louisville international airport
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00:01:00,594 --> 00:01:03,495
Is one of the busiest airports
in the country
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And the fourth busiest
in the world.
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So it's no surprise that this
facility is also home
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To worldport,
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The united parcel service's
very own air terminal.
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Handling more than
300 flights daily,
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00:01:22,450 --> 00:01:26,552
This supercenter processes
2 million packages a day,
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00:01:26,554 --> 00:01:30,689
Making it the largest automated
sorting hub on the planet.
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00:01:33,060 --> 00:01:36,962
Inside this 5.4 million
square foot home,
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00:01:36,964 --> 00:01:41,733
Billions of packages are sorted
across nearly 155 miles
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00:01:41,735 --> 00:01:45,637
Of computer-controlled
conveyor belts.
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00:01:45,639 --> 00:01:48,107
Monitored by trained operators,
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Packages are sorted through
a highly automated process,
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Then flown to their destinations
all around the world.
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I don't know that everybody
maybe fully realizes
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00:02:00,287 --> 00:02:01,987
That ups is also an airline.
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00:02:01,989 --> 00:02:03,755
Everyone knows us
for our drivers
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00:02:03,757 --> 00:02:05,924
And that great relationship
that they have,
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00:02:05,926 --> 00:02:08,794
But we're also this
massive airline as well.
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00:02:08,796 --> 00:02:10,562
It's just such a unique process.
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They come in, they unload,
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00:02:12,032 --> 00:02:16,702
They're back out, getting
those packages around the world.
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Narrator: Here at worldport,
it takes just 13 minutes
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00:02:20,441 --> 00:02:25,644
To move a package from
an inbound to outbound flight.
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00:02:25,646 --> 00:02:29,014
Achieving such a fast
turnaround is only possible
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00:02:29,016 --> 00:02:33,152
By using an intense level
of automation.
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00:02:33,154 --> 00:02:35,487
We only want our employees
to touch a package
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On two occasions --
when they unload it
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00:02:37,691 --> 00:02:39,958
And place it
into the parcel system
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00:02:39,960 --> 00:02:41,560
And when they loaded
on the outbound side,
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00:02:41,562 --> 00:02:44,830
Placing it in a container.
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00:02:44,832 --> 00:02:47,599
Narrator:
Since it opened in 2002,
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Worldport has expanded twice
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00:02:49,737 --> 00:02:53,739
And is now over 6.8 miles long.
51
00:02:55,075 --> 00:02:57,709
The global parcels market
has tripled in size
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00:02:57,711 --> 00:02:59,578
In the last five years.
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00:02:59,580 --> 00:03:03,916
It's now worth
over $350 billion.
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00:03:03,918 --> 00:03:07,886
Narrator: Success or failure
depends on speed.
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00:03:07,888 --> 00:03:09,555
To stay ahead of schedule,
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00:03:09,557 --> 00:03:14,593
Ups utilizes
a fleet of 550 aircraft.
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00:03:14,595 --> 00:03:17,596
These planes don't carry
a single passenger,
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00:03:17,598 --> 00:03:20,032
But they do fly
to more destinations
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00:03:20,034 --> 00:03:22,768
Than any other airline
in the world.
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It's a far cry
from the very first
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Trans-american mail service,
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00:03:29,810 --> 00:03:31,977
The pony express,
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00:03:31,979 --> 00:03:36,381
Which got its start
in April of 1860.
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00:03:36,383 --> 00:03:38,517
Gough:
Couriers rode on horseback
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00:03:38,519 --> 00:03:40,552
And were able to
transport packages
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00:03:40,554 --> 00:03:44,523
All across the u.S.
In just 10 days.
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00:03:44,525 --> 00:03:46,558
It only lasted 18 months
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00:03:46,560 --> 00:03:51,129
Because it was superseded
by the telegram.
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Narrator:
But there was still a market
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00:03:54,101 --> 00:03:55,934
For delivering packages.
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00:03:55,936 --> 00:03:58,470
In 1907, jim casey borrowed $100
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00:03:58,472 --> 00:04:01,974
And started a shoestring
operation in seattle.
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00:04:01,976 --> 00:04:07,579
It soon became known as ups,
the united parcel service.
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00:04:07,581 --> 00:04:12,251
Today, the company is based
in louisville for a reason.
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00:04:12,253 --> 00:04:15,187
This centrally situated city
is located no more
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00:04:15,189 --> 00:04:19,891
Than two hours from 75%
of the u.S. Population.
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And from this hub,
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00:04:21,562 --> 00:04:25,264
Flights head out to destinations
all around the world.
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Worldport has the process
down to a science.
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00:04:31,672 --> 00:04:34,139
When flights
containing cargo arrive,
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00:04:34,141 --> 00:04:36,541
The containers are taken
off the planes
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00:04:36,543 --> 00:04:41,013
And loaded onto the cargo
holding area.
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00:04:41,015 --> 00:04:43,949
It may look like these
containers are lightweight,
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00:04:43,951 --> 00:04:47,519
But that's because the floor is
covered with embedded rollers.
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00:04:49,423 --> 00:04:51,823
They allow the package handlers
to quickly move
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00:04:51,825 --> 00:04:54,526
The containers
weighing over 2 tons
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Throughout the facility
with ease.
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The containers are then pulled
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00:04:59,967 --> 00:05:03,635
To one of the 377
unloading stations.
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00:05:04,905 --> 00:05:07,873
The packages inside need
to be quickly sorted,
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00:05:07,875 --> 00:05:11,576
Moved across the terminal and
dispatched to the outbound plane
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00:05:11,578 --> 00:05:16,214
That is waiting to fly them
to their final destinations.
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00:05:16,216 --> 00:05:17,616
Once on the belt,
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00:05:17,618 --> 00:05:22,254
The packages begin their journey
across the facility.
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Packages are placed
on one of three conveyor belts,
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00:05:25,492 --> 00:05:29,461
Depending on the size
of the package.
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00:05:29,463 --> 00:05:32,631
So this box is basically
a normal-size box,
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00:05:32,633 --> 00:05:34,633
So it would go up
the main parcel belt.
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00:05:34,635 --> 00:05:36,134
And then you have
these bags here
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00:05:36,136 --> 00:05:39,504
That are small that would go up
this belt over here.
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00:05:41,909 --> 00:05:44,075
And then these ones here
that are a little bit bigger,
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We call these the e-rig packages
and they go on this belt here
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00:05:47,915 --> 00:05:50,315
To be processed upstairs
because they're so big.
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00:05:51,985 --> 00:05:55,020
Narrator: The key to identifying
the incoming packages
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00:05:55,022 --> 00:05:58,056
And moving them towards
the correct outgoing flight
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00:05:58,058 --> 00:06:00,659
Is the barcode.
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00:06:00,661 --> 00:06:04,596
Barcodes are based on the same
principle as morse code,
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00:06:04,598 --> 00:06:07,032
Where you've got
a series of dots and dashes
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That electronically
communicate information,
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00:06:09,603 --> 00:06:11,069
And then the barcode was born
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00:06:11,071 --> 00:06:12,738
Because it took those dots
and dashes
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00:06:12,740 --> 00:06:14,940
And turned them into thick
and thin lines
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00:06:14,942 --> 00:06:18,844
And used those thick and thin
lines to send that information.
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Narrator: Once a package's
barcode is scanned
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00:06:21,215 --> 00:06:23,415
And its destination
is identified,
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00:06:23,417 --> 00:06:24,616
An automated system
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00:06:24,618 --> 00:06:29,254
Determines the fastest route
across the hub.
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00:06:29,256 --> 00:06:32,290
As packages speed
along the conveyor belts,
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00:06:32,292 --> 00:06:35,961
Cameras scan their barcodes
to keep them on the right track.
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00:06:37,831 --> 00:06:40,966
The technology,
the smart labels are really key
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00:06:40,968 --> 00:06:43,201
To feeding in the brain of ups,
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00:06:43,203 --> 00:06:46,004
Which is the control center
that's tracking the volume flow,
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00:06:46,006 --> 00:06:47,539
It's tracking the packages,
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00:06:47,541 --> 00:06:49,408
And that's what
those camera tunnels are doing
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00:06:49,410 --> 00:06:51,042
Every time
they scan that package,
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00:06:51,044 --> 00:06:54,679
They're making sure that it's
going to where it needs to go.
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00:06:54,681 --> 00:06:56,448
Narrator:
When they read the barcode,
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00:06:56,450 --> 00:06:59,484
Special automated sorters
called pucks
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00:06:59,486 --> 00:07:01,553
Integrated into the belt system
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00:07:01,555 --> 00:07:05,257
Send the parcels in the right
direction and to the next belt.
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00:07:08,262 --> 00:07:09,828
If there's any problem,
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00:07:09,830 --> 00:07:12,097
Controllers can remotely move
the pucks
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00:07:12,099 --> 00:07:15,734
To get the parcel exactly
where it needs to be.
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00:07:15,736 --> 00:07:17,402
Schaefer: If there's any issues,
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00:07:17,404 --> 00:07:19,271
They can adjust that
on the fly.
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00:07:19,273 --> 00:07:20,572
Point and click.
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00:07:20,574 --> 00:07:23,375
So the next time that package
hits a camera read,
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00:07:23,377 --> 00:07:24,509
It's been fixed.
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00:07:24,511 --> 00:07:27,145
It picks up a good read
on the label
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00:07:27,147 --> 00:07:30,449
To keep all the flow moving.
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00:07:30,451 --> 00:07:33,218
Narrator: The parcels that were
loaded on to the belt
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00:07:33,220 --> 00:07:37,823
Approach the dispatch point
for their outbound flights.
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00:07:37,825 --> 00:07:40,225
Now, the pucks knock the parcels
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00:07:40,227 --> 00:07:43,094
Into the airside cargo
loading bay.
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00:07:43,096 --> 00:07:48,967
♪♪
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00:07:48,969 --> 00:07:51,570
Although this factory
is highly automated,
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00:07:51,572 --> 00:07:54,639
It's remarkable just how
many handlers are still needed
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00:07:54,641 --> 00:07:56,741
To keep these packages moving.
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00:07:59,713 --> 00:08:02,514
10,000 people work here.
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00:08:02,516 --> 00:08:07,018
It's mostly the small packages
that need the human touch.
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00:08:07,020 --> 00:08:09,654
Package handlers direct
individual items
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00:08:09,656 --> 00:08:14,392
Onto a conveyor belt
using a tilt tray system.
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00:08:14,394 --> 00:08:18,029
There are 17,220 trays.
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00:08:18,031 --> 00:08:22,300
Each carries only one package
at a time.
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00:08:22,302 --> 00:08:25,036
But the label must be face up.
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00:08:25,038 --> 00:08:27,372
The reason why it's important
for the labels
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00:08:27,374 --> 00:08:30,675
To be up on the tilt tray
is because
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00:08:30,677 --> 00:08:32,310
Once that person touches it
and puts it there,
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00:08:32,312 --> 00:08:33,578
At that point,
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00:08:33,580 --> 00:08:35,847
It's not gonna be seen
by a human being again.
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00:08:35,849 --> 00:08:37,315
It's gonna go through
scan tunnels,
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00:08:37,317 --> 00:08:40,452
Directing it where it needs
to go based off the information
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00:08:40,454 --> 00:08:44,489
On that very simple-looking
smart label.
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00:08:44,491 --> 00:08:47,692
Narrator: The tilt trays are
crucial because they present
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00:08:47,694 --> 00:08:50,161
The many and varied shapes
of the small packages
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To the scanner in a uniform way.
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00:08:53,834 --> 00:08:56,601
But if the camera system
can't read the label,
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00:08:56,603 --> 00:08:59,905
An image of it
is sent to a monitoring station.
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00:08:59,907 --> 00:09:03,675
Sometimes a shipper
will have a bad printer.
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00:09:03,677 --> 00:09:06,945
And when they print their label
out, there will be a line.
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00:09:06,947 --> 00:09:10,248
There'll be something wrong
with the barcode.
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00:09:10,250 --> 00:09:13,885
So when it gets to us,
it's not reading correctly.
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00:09:13,887 --> 00:09:16,321
Narrator:
As soon as the image appears,
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00:09:16,323 --> 00:09:18,757
The monitoring team
has just 10 seconds
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00:09:18,759 --> 00:09:21,760
To identify the zip code
on the label
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00:09:21,762 --> 00:09:24,329
And manually
redirect the package
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00:09:24,331 --> 00:09:26,731
To the appropriate loading area.
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00:09:26,733 --> 00:09:29,167
If neither the scanner
nor the monitoring team
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00:09:29,169 --> 00:09:31,336
Can identify the label,
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00:09:31,338 --> 00:09:35,173
The rogue package must be
tracked down and inspected.
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00:09:37,444 --> 00:09:40,078
From the first belt
until this point,
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A package would have traveled
through the facility
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00:09:42,416 --> 00:09:44,649
For less than 15 minutes.
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00:09:48,121 --> 00:09:50,922
Once the package reaches
its destination,
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00:09:50,924 --> 00:09:53,058
A computer signals the tilt tray
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00:09:53,060 --> 00:09:56,127
To eject the package
into a canvas bag.
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00:09:57,864 --> 00:10:00,999
The packages have finally
made it to airside,
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00:10:01,001 --> 00:10:02,534
But there's one more step
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00:10:02,536 --> 00:10:06,104
Before they're ready
for their outbound flights.
190
00:10:06,106 --> 00:10:09,407
At outbound, workers load
and stack packages
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00:10:09,409 --> 00:10:11,743
In the cargo containers.
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00:10:11,745 --> 00:10:15,113
This step can only be done
by humans.
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00:10:15,115 --> 00:10:18,149
The smaller boxes like this,
I put around the bigger boxes
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00:10:18,151 --> 00:10:20,151
To make sure that it fills
in the spaces
195
00:10:20,153 --> 00:10:22,287
And I have to build up
from the back wall
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00:10:22,289 --> 00:10:26,558
And then the sides
and then fill outward.
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00:10:26,560 --> 00:10:29,160
Narrator:
After a final visual inspection,
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00:10:29,162 --> 00:10:31,696
Handlers transport
the loaded containers
199
00:10:31,698 --> 00:10:33,598
Into the cargo hold
of the plane.
200
00:10:36,303 --> 00:10:39,137
When in position
inside the aircraft,
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00:10:39,139 --> 00:10:41,306
Containers lock into place
202
00:10:41,308 --> 00:10:44,209
To avoid
moving around in flight.
203
00:10:44,211 --> 00:10:47,812
Within minutes,
this flight will be airbound.
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00:10:50,150 --> 00:10:52,517
From unloading to reloading,
205
00:10:52,519 --> 00:10:57,589
The entire sorting process
takes, at most, 45 minutes.
206
00:10:57,591 --> 00:11:00,959
Even though most of the sorting
is performed automatically,
207
00:11:00,961 --> 00:11:05,530
Package handlers are
a crucial part of the process.
208
00:11:05,532 --> 00:11:10,502
On a normal day, this facility
sorts 2 million packages.
209
00:11:10,504 --> 00:11:14,572
During the holidays, the teams
here go into overdrive,
210
00:11:14,574 --> 00:11:19,244
Sorting as many as 4 million
packages a day.
211
00:11:20,280 --> 00:11:23,715
The workforce at worldport is
dedicated to ensuring packages
212
00:11:23,717 --> 00:11:27,185
Are delivered to
their destinations on time.
213
00:11:27,187 --> 00:11:30,989
And it's their ability to mix
manpower with modernity
214
00:11:30,991 --> 00:11:34,693
That makes this factory
a super factory.
215
00:11:37,597 --> 00:11:41,366
Coming up, a culinary explosion
in korea.
216
00:11:41,368 --> 00:11:45,303
Their invention was actually
a breakthrough in food science.
217
00:11:45,305 --> 00:11:46,705
Narrator: And later,
218
00:11:46,707 --> 00:11:49,708
In the highly competitive
international bicycle market,
219
00:11:49,710 --> 00:11:54,279
One unique set of wheels
stands out from the rest.
220
00:11:54,281 --> 00:11:57,949
It's instantly recognizable,
a design icon.
221
00:12:00,520 --> 00:12:06,124
♪♪
222
00:12:06,126 --> 00:12:11,763
♪♪
223
00:12:11,765 --> 00:12:13,698
Narrator: Mankind has
accomplished
224
00:12:13,700 --> 00:12:16,501
Many remarkable things
during the course of history --
225
00:12:16,503 --> 00:12:20,238
Space exploration,
226
00:12:20,240 --> 00:12:22,340
The jet engine,
227
00:12:22,342 --> 00:12:24,442
The automobile,
228
00:12:24,444 --> 00:12:27,779
The grand piano.
229
00:12:27,781 --> 00:12:31,549
But this surprising culinary
staple may just rank
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00:12:31,551 --> 00:12:35,253
Among man's
greatest achievements.
231
00:12:35,255 --> 00:12:37,989
The world has
an undeniable hunger
232
00:12:37,991 --> 00:12:40,859
For instant noodles.
233
00:12:40,861 --> 00:12:42,427
Outside of asia,
234
00:12:42,429 --> 00:12:46,498
The u.S. Is the largest consumer
of instant noodles.
235
00:12:46,500 --> 00:12:50,735
In 2018,
280 million servings
236
00:12:50,737 --> 00:12:55,106
Were consumed worldwide
every single day.
237
00:12:55,108 --> 00:12:58,309
But the country with the world's
most voracious appetite
238
00:12:58,311 --> 00:13:02,147
For noodles is south korea.
239
00:13:02,149 --> 00:13:05,550
Over 51 million people
live in this country
240
00:13:05,552 --> 00:13:08,286
And each person
consumes at least
241
00:13:08,288 --> 00:13:11,156
One and a half servings
every week.
242
00:13:11,158 --> 00:13:13,892
And this massive factory
in gumi,
243
00:13:13,894 --> 00:13:17,495
124 miles south of the capital,
seoul,
244
00:13:17,497 --> 00:13:20,732
Is working hard
to keep up with demand.
245
00:13:20,734 --> 00:13:24,302
The plant, owned by
the nongshim corporation,
246
00:13:24,304 --> 00:13:27,438
Pumps out a staggering
5 million packs
247
00:13:27,440 --> 00:13:31,042
Of instant noodles every week.
248
00:13:31,044 --> 00:13:34,779
But these aren't
your average noodles.
249
00:13:34,781 --> 00:13:37,081
Noodles are made
from wheat flour.
250
00:13:37,083 --> 00:13:38,917
And like pasta or spaghetti,
251
00:13:38,919 --> 00:13:41,853
They'll keep for months
or for years.
252
00:13:41,855 --> 00:13:44,022
Now, the difference
between an instant noodle
253
00:13:44,024 --> 00:13:46,991
And an ordinary noodle
is that instant noodle
254
00:13:46,993 --> 00:13:50,128
Has gone through a series
of processes in the factory,
255
00:13:50,130 --> 00:13:52,163
Which means it will be ready
to eat
256
00:13:52,165 --> 00:13:54,432
Just by adding boiling water.
257
00:13:54,434 --> 00:13:57,168
There's no need to cook it.
258
00:13:57,170 --> 00:13:59,103
Narrator:
At this super factory,
259
00:13:59,105 --> 00:14:02,607
The workforce has noodle-making
down to a science.
260
00:14:05,545 --> 00:14:09,614
The main raw ingredient --
flour -- arrives in tankers.
261
00:14:11,852 --> 00:14:17,222
This plant goes through millions
of tons of flour every year.
262
00:14:17,224 --> 00:14:19,691
It's pumped into the factory
at high speed
263
00:14:19,693 --> 00:14:21,759
Through a network of pipes.
264
00:14:25,632 --> 00:14:28,833
The flour is mixed
with warm water
265
00:14:28,835 --> 00:14:31,870
And then salt is added.
266
00:14:31,872 --> 00:14:36,107
This creates a noodle dough,
which is kneaded for 15 minutes.
267
00:14:38,478 --> 00:14:41,279
Kneading is an essential part
of making any dough.
268
00:14:41,281 --> 00:14:45,583
It's the process by which gluten
is developed inside the mix,
269
00:14:45,585 --> 00:14:47,485
And gluten is that material
270
00:14:47,487 --> 00:14:49,988
That gives elasticity
to a dough.
271
00:14:49,990 --> 00:14:52,390
And that will help you make
noodles that can be very thin
272
00:14:52,392 --> 00:14:55,426
And very long and have a good
sort of bite to them.
273
00:14:55,428 --> 00:15:00,899
♪♪
274
00:15:00,901 --> 00:15:03,201
Narrator: The kneaded dough
is rolled into a layer
275
00:15:03,203 --> 00:15:05,303
Less than a half an inch thick.
276
00:15:08,375 --> 00:15:12,410
It then passes through four
different roller systems.
277
00:15:12,412 --> 00:15:14,112
Each successive roller
278
00:15:14,114 --> 00:15:16,915
Gradually makes
the dough thinner and thinner
279
00:15:16,917 --> 00:15:20,151
Until it's just
one millimeter thick.
280
00:15:20,153 --> 00:15:22,487
Instant noodles are
one of those things
281
00:15:22,489 --> 00:15:24,222
We just take for granted now.
282
00:15:24,224 --> 00:15:28,726
But their invention was actually
a breakthrough in food science.
283
00:15:28,728 --> 00:15:31,429
Narrator: In fact,
it was nothing short
284
00:15:31,431 --> 00:15:33,097
Of a culinary revolution.
285
00:15:33,099 --> 00:15:35,099
Gough:
It's an amazing phenomenon.
286
00:15:35,101 --> 00:15:36,701
The method for making
instant noodles
287
00:15:36,703 --> 00:15:40,638
Was actually invented
in japan in 1958.
288
00:15:40,640 --> 00:15:44,075
20 years ago,
a major research institute asked
289
00:15:44,077 --> 00:15:45,543
Japanese citizens
290
00:15:45,545 --> 00:15:49,314
To list their country's
greatest inventions.
291
00:15:49,316 --> 00:15:53,017
They didn't vote for personal
stereos or computer games.
292
00:15:53,019 --> 00:15:58,056
No, their number-one choice
was instant noodles.
293
00:15:58,058 --> 00:16:02,794
Narrator: At this stage, the
dough is just a big, flat sheet.
294
00:16:02,796 --> 00:16:07,799
So now it's time to start
making it into a noodle shape.
295
00:16:07,801 --> 00:16:11,202
To do that, the dough
goes through a slitter machine.
296
00:16:11,204 --> 00:16:15,873
Here, a blade slits that big,
thin sheet into long strips.
297
00:16:15,875 --> 00:16:19,143
What emerges is
a wavy-looking tangle.
298
00:16:19,145 --> 00:16:21,145
Russell: The chemistry
behind them
299
00:16:21,147 --> 00:16:22,747
Is not as simple as it looks.
300
00:16:22,749 --> 00:16:26,751
That characteristic wavy shape
is no accident.
301
00:16:26,753 --> 00:16:29,887
It helps prevent the noodles
from sticking together.
302
00:16:29,889 --> 00:16:32,890
And also because
it creates more surface area,
303
00:16:32,892 --> 00:16:35,093
It means when you add
boiling water,
304
00:16:35,095 --> 00:16:39,564
The noodles reconstitute
and soften more quickly.
305
00:16:39,566 --> 00:16:41,499
Narrator: After stretching,
306
00:16:41,501 --> 00:16:44,535
The strands of noodles
with about 43% moisture
307
00:16:44,537 --> 00:16:47,905
Are conveyed
through a steam tunnel.
308
00:16:47,907 --> 00:16:50,842
Inside, the noodles are steamed
at a temperature
309
00:16:50,844 --> 00:16:56,214
Of approximately 212 degrees
for 1 to 3 minutes.
310
00:16:56,216 --> 00:16:58,649
Steam power is used
instead of gas
311
00:16:58,651 --> 00:17:02,353
For more precise
temperature control.
312
00:17:02,355 --> 00:17:07,792
The steaming process starts
a critical chemical reaction.
313
00:17:07,794 --> 00:17:10,128
When the noodle is cooked,
the starch inside
314
00:17:10,130 --> 00:17:11,963
Actually starts to break down,
315
00:17:11,965 --> 00:17:14,699
It goes through
a process of gelatinization.
316
00:17:14,701 --> 00:17:16,934
Well, gelatinization is
basically
317
00:17:16,936 --> 00:17:19,871
When the starch molecules
start to bond with each other
318
00:17:19,873 --> 00:17:23,474
And change
and become jellylike.
319
00:17:23,476 --> 00:17:27,445
And actually, that's what gives
the noodle its desired texture.
320
00:17:28,548 --> 00:17:29,847
Narrator: From the steamer,
321
00:17:29,849 --> 00:17:33,184
The noodles move down the belt
into a dipping bath,
322
00:17:33,186 --> 00:17:35,520
Where they're seasoned,
323
00:17:35,522 --> 00:17:39,157
But the noodles
aren't ready to eat yet.
324
00:17:39,159 --> 00:17:41,025
Before they're ready
to be packaged,
325
00:17:41,027 --> 00:17:43,561
They must go through
an essential process
326
00:17:43,563 --> 00:17:46,464
To withstand the tests of time.
327
00:17:52,772 --> 00:17:54,672
Narrator: For over 50 years,
328
00:17:54,674 --> 00:17:58,509
Nongshim has pioneered
culinary culture in south korea
329
00:17:58,511 --> 00:18:01,412
By combining modern technology
and science
330
00:18:01,414 --> 00:18:04,449
With authentic
korean cuisine.
331
00:18:04,451 --> 00:18:08,186
One of their most popular
products, instant noodle soup,
332
00:18:08,188 --> 00:18:13,024
Has propelled the company
to the top of the industry.
333
00:18:13,026 --> 00:18:15,927
Nongshim is currently
the largest instant noodles
334
00:18:15,929 --> 00:18:18,229
And snack company
in south korea.
335
00:18:20,500 --> 00:18:24,235
Asia is still the biggest
market for instant noodles.
336
00:18:24,237 --> 00:18:26,370
10 of the top 15 countries
337
00:18:26,372 --> 00:18:28,873
That consume
instant noodles are asian,
338
00:18:28,875 --> 00:18:32,443
But the biggest non-asian
country is the united states,
339
00:18:32,445 --> 00:18:36,314
Where 4 1/2 billion portions
of instant noodles
340
00:18:36,316 --> 00:18:38,983
Were eaten in 2018 alone.
341
00:18:38,985 --> 00:18:43,621
So why did they catch on
in korea in such a big way?
342
00:18:43,623 --> 00:18:47,024
They took off in the early 1960s
when the country
343
00:18:47,026 --> 00:18:50,928
Was still recovering
from war on the peninsula.
344
00:18:50,930 --> 00:18:55,800
Food was pretty scarce,
but so was fuel for cooking.
345
00:18:55,802 --> 00:18:58,236
So instant noodles,
which you can prepare
346
00:18:58,238 --> 00:19:02,807
In just a few minutes weren't
looked at as a convenience.
347
00:19:02,809 --> 00:19:06,477
They were an absolute necessity.
348
00:19:06,479 --> 00:19:08,913
Narrator: Noodles are associated
with the east,
349
00:19:08,915 --> 00:19:12,517
But many experts agree
they have a western cousin.
350
00:19:12,519 --> 00:19:15,920
Noodles and pasta
are essentially the same thing.
351
00:19:15,922 --> 00:19:19,423
There's a legend that marco polo
brought back the secret
352
00:19:19,425 --> 00:19:22,426
To europe
after his travels in china,
353
00:19:22,428 --> 00:19:24,162
But that's not true.
354
00:19:24,164 --> 00:19:27,865
It's much more likely that pasta
was developed in sicily
355
00:19:27,867 --> 00:19:31,235
Around 1,000 years ago.
356
00:19:31,237 --> 00:19:35,740
Narrator: The history of instant
noodles dates back to 1958.
357
00:19:35,742 --> 00:19:38,342
The inventor, momofuku ando,
358
00:19:38,344 --> 00:19:41,179
Perfected the craft
after a year of research
359
00:19:41,181 --> 00:19:45,116
Using common tools in a shed
he built in his own backyard.
360
00:19:47,820 --> 00:19:51,055
Today, thanks to
ando's creativity,
361
00:19:51,057 --> 00:19:53,057
The secret to this company's
success
362
00:19:53,059 --> 00:19:56,027
Can be found
inside their factories
363
00:19:56,029 --> 00:20:01,532
Using the same techniques that
ando created over 60 years ago.
364
00:20:02,702 --> 00:20:04,569
Back on the assembly line,
365
00:20:04,571 --> 00:20:10,007
The noodles are chopped into
roughly 16- to 28-inch portions.
366
00:20:10,009 --> 00:20:12,777
Each one is dropped
into a metal bowl,
367
00:20:12,779 --> 00:20:15,713
Which acts as a circular mold.
368
00:20:15,715 --> 00:20:18,249
Once they're in the molds,
369
00:20:18,251 --> 00:20:22,119
The noodles are fried
in 239-degree oil
370
00:20:22,121 --> 00:20:24,755
For exactly 72 seconds.
371
00:20:24,857 --> 00:20:26,490
[ speaking korean ]
372
00:20:42,141 --> 00:20:44,175
Russell: You might think,
"why fry them?"
373
00:20:44,177 --> 00:20:46,477
Well, frying them
actually takes down
374
00:20:46,479 --> 00:20:49,513
The moisture content
to about 5%.
375
00:20:51,451 --> 00:20:53,618
Narrator: Most instant noodles
are dehydrated,
376
00:20:53,620 --> 00:20:57,154
Either by oil-frying
or air-drying.
377
00:20:57,156 --> 00:20:59,323
These noodles are fried in oil.
378
00:21:01,227 --> 00:21:03,194
Reducing the water content
379
00:21:03,196 --> 00:21:06,664
Is absolutely crucial
for the next step --
380
00:21:06,666 --> 00:21:09,100
Dehydration.
381
00:21:09,102 --> 00:21:12,903
Dehydrating is a key part
of preserving the noodles.
382
00:21:12,905 --> 00:21:15,539
The dried noodles could sit
in their packets for months
383
00:21:15,541 --> 00:21:17,675
Before they're prepared.
384
00:21:17,677 --> 00:21:21,846
Any excess water
would reduce their shelf life.
385
00:21:21,848 --> 00:21:25,416
After the noodles have
been fried and dehydrated,
386
00:21:25,418 --> 00:21:27,685
They're cooled.
387
00:21:27,687 --> 00:21:29,153
The cooling process is followed
388
00:21:29,155 --> 00:21:34,191
By a series of careful
inspections for weight, shape,
389
00:21:34,193 --> 00:21:38,262
Color, frying condition,
and temperature.
390
00:21:38,264 --> 00:21:40,231
Products are
automatically eliminated
391
00:21:40,233 --> 00:21:44,135
From the assembly line
if a metal material is detected
392
00:21:44,137 --> 00:21:47,305
Or their weight is out
of the preset range.
393
00:21:49,075 --> 00:21:53,511
Finally, the noodles
are packed into film bags.
394
00:21:54,947 --> 00:21:56,714
Finished products
are automatically
395
00:21:56,716 --> 00:22:00,284
Put into cardboard cases.
396
00:22:00,286 --> 00:22:02,820
Now the only thing left to do
397
00:22:02,822 --> 00:22:05,856
Is to ship them out
to the consumer.
398
00:22:05,858 --> 00:22:08,959
This factory outputs
700,000 packets
399
00:22:08,961 --> 00:22:12,063
Of instant noodles every day.
400
00:22:13,032 --> 00:22:15,299
Today, nongshim's
instant noodles
401
00:22:15,301 --> 00:22:19,470
Have come to define
korean ramen cuisine.
402
00:22:19,472 --> 00:22:20,671
Since its creation,
403
00:22:20,673 --> 00:22:25,009
More than 22 billion bags
have been sold.
404
00:22:25,011 --> 00:22:28,312
Globally, korea is among
the largest consumers
405
00:22:28,314 --> 00:22:29,847
Of instant ramen,
406
00:22:29,849 --> 00:22:33,317
Consuming 80 bags
per person annually.
407
00:22:33,319 --> 00:22:37,221
That's about one bag
every five days.
408
00:22:37,223 --> 00:22:39,857
And thanks to this
super factory,
409
00:22:39,859 --> 00:22:43,060
Demand is still on the rise.
410
00:22:44,130 --> 00:22:48,099
Coming up, the transformer
of the bike world.
411
00:22:48,101 --> 00:22:55,306
This bike is actually made up
of 1,200 parts.
412
00:22:55,308 --> 00:22:58,943
Narrator: And later, a small
family-run business is moving
413
00:22:58,945 --> 00:23:02,747
Into a technological,
brave new world.
414
00:23:02,749 --> 00:23:04,949
They were nominated as part
of a global network
415
00:23:04,951 --> 00:23:07,718
Of so-called
manufacturing lighthouses.
416
00:23:10,890 --> 00:23:17,128
♪♪
417
00:23:17,130 --> 00:23:23,334
♪♪
418
00:23:23,336 --> 00:23:25,035
Narrator: In london, England,
419
00:23:25,037 --> 00:23:28,406
A quirky-looking device
with a unique selling point
420
00:23:28,408 --> 00:23:30,541
Is being assembled
using techniques
421
00:23:30,543 --> 00:23:35,146
That aren't found
in any other factories.
422
00:23:35,148 --> 00:23:38,849
This is a brompton,
423
00:23:38,851 --> 00:23:42,319
The transformer
of the bike world.
424
00:23:42,321 --> 00:23:45,756
This bike
is actually made up
425
00:23:45,758 --> 00:23:49,326
Of 1,200 parts.
426
00:23:50,763 --> 00:23:53,497
Narrator: Bromptons are the
ultimate purpose-built tool
427
00:23:53,499 --> 00:23:57,368
For commuting
in an urban environment.
428
00:23:57,370 --> 00:24:00,771
This tiny-wheeled,
unconventional-looking bike
429
00:24:00,773 --> 00:24:03,407
Has one of the most
enthusiastic followings
430
00:24:03,409 --> 00:24:05,843
In the cycling industry.
431
00:24:05,845 --> 00:24:08,846
Demand for these bikes
is growing so fast
432
00:24:08,848 --> 00:24:12,783
That brompton's
86,000-square-foot london site
433
00:24:12,785 --> 00:24:16,821
Is now britain's newest
and biggest bicycle factory.
434
00:24:20,693 --> 00:24:22,993
Inside this super factory,
435
00:24:22,995 --> 00:24:27,064
Over 1,000 folding bikes
are made by hand each week.
436
00:24:28,167 --> 00:24:31,502
With a growing following
in asia and north america,
437
00:24:31,504 --> 00:24:38,108
This super factory is on track
to produce 100,000 bikes a year.
438
00:24:38,110 --> 00:24:41,679
Brompton is really an amazing
industrial "phoenix
439
00:24:41,681 --> 00:24:44,582
Rising from the ashes"
kind of story.
440
00:24:44,584 --> 00:24:49,887
In the 1970s, due to the import
of low-cost asian bikes,
441
00:24:49,889 --> 00:24:54,859
The british bicycle industry
pretty much crashed and burned.
442
00:24:54,861 --> 00:24:58,362
Narrator: British manufacturers
simply couldn't compete on cost.
443
00:24:58,364 --> 00:25:01,966
The only option was to think
outside of the box.
444
00:25:01,968 --> 00:25:04,969
So to fight back, they had to
come up with something new,
445
00:25:04,971 --> 00:25:07,571
Something different,
something eye-catching
446
00:25:07,573 --> 00:25:10,708
And maybe something that people
didn't even know they wanted.
447
00:25:10,710 --> 00:25:12,910
The brompton ticks
all of those boxes.
448
00:25:12,912 --> 00:25:15,279
And ironically, this u.K. Firm
449
00:25:15,281 --> 00:25:20,751
Is now exporting large numbers
of bikes to asia.
450
00:25:20,753 --> 00:25:22,887
Narrator: The invention
of the brompton bike
451
00:25:22,889 --> 00:25:27,091
Was first conceived by cambridge
university engineering graduate
452
00:25:27,093 --> 00:25:29,260
Andrew ritchie.
453
00:25:29,262 --> 00:25:32,630
Ritchie's obsession
with bikes began in 1975
454
00:25:32,632 --> 00:25:35,399
When he came across
a unique bike model
455
00:25:35,401 --> 00:25:38,469
And thought he could
improve upon it.
456
00:25:38,471 --> 00:25:42,172
He eventually designed a bike
that was surprisingly light,
457
00:25:42,174 --> 00:25:44,675
Small enough to fit
in an apartment,
458
00:25:44,677 --> 00:25:46,644
Easier to manufacture
459
00:25:46,646 --> 00:25:50,381
And completely customizable
for the consumer.
460
00:25:50,383 --> 00:25:52,216
Over the next four years,
461
00:25:52,218 --> 00:25:53,918
Ritchie carved out
a niche market
462
00:25:53,920 --> 00:25:57,087
For enthusiasts
for the folding bike.
463
00:25:57,089 --> 00:26:01,392
And in 1979,
he patented his design,
464
00:26:01,394 --> 00:26:06,363
Which is still the template
for all brompton bikes today.
465
00:26:06,365 --> 00:26:09,967
The inventor, andrew,
and one other guy,
466
00:26:09,969 --> 00:26:12,336
Patty, started making bikes.
467
00:26:12,338 --> 00:26:16,540
It took them 2 years
to make 400 bikes.
468
00:26:16,542 --> 00:26:20,144
We're currently making
300 bikes a day.
469
00:26:22,782 --> 00:26:26,750
Narrator: Inside this factory,
a highly skilled team of workers
470
00:26:26,752 --> 00:26:29,753
Are reviving traditional
metal-working methods
471
00:26:29,755 --> 00:26:32,723
Rarely seen
in modern factories.
472
00:26:33,826 --> 00:26:36,393
The process starts
with steel tubes
473
00:26:36,395 --> 00:26:39,330
That will soon be machined
together into a frame
474
00:26:39,332 --> 00:26:43,734
Using a joining technique
called brazing.
475
00:26:43,736 --> 00:26:45,202
Brazing is a lost art.
476
00:26:45,204 --> 00:26:47,504
It's the ability to bond
two materials together,
477
00:26:47,506 --> 00:26:49,006
But at a low temperature.
478
00:26:49,008 --> 00:26:51,475
The bond is stronger
because you get less shrinkage
479
00:26:51,477 --> 00:26:54,411
Of the bonding material.
480
00:26:54,413 --> 00:26:56,981
Narrator:
Each bike is hand-brazed.
481
00:26:56,983 --> 00:26:59,216
This process is similar
to welding
482
00:26:59,218 --> 00:27:02,586
But uses lower temperatures
and doesn't melt the metal
483
00:27:02,588 --> 00:27:05,255
That is being joined together.
484
00:27:05,257 --> 00:27:07,224
Summer:
You have to learn temperatures.
485
00:27:07,226 --> 00:27:10,928
You have to learn how
the components join together
486
00:27:10,930 --> 00:27:14,565
Because you want a bike
that lasts years and years.
487
00:27:14,567 --> 00:27:16,300
It's your responsibility
to keep people safe,
488
00:27:16,302 --> 00:27:21,238
So it's important to have
a really, really strong braze.
489
00:27:21,240 --> 00:27:23,140
Narrator:
Once the frame is put together,
490
00:27:23,142 --> 00:27:26,043
It's ready to be painted.
491
00:27:26,045 --> 00:27:29,480
For the first 20 years
after launching on the market,
492
00:27:29,482 --> 00:27:34,118
These bikes only came
in either red or black.
493
00:27:34,120 --> 00:27:36,220
Today, bromptons
are available
494
00:27:36,222 --> 00:27:39,556
In a huge range
of color combinations,
495
00:27:39,558 --> 00:27:41,825
And the paint they use
is special
496
00:27:41,827 --> 00:27:44,628
Because it's not wet.
497
00:27:44,630 --> 00:27:46,230
Brompton uses
a dry coating process
498
00:27:46,232 --> 00:27:48,565
Called electrostatic
painting.
499
00:27:48,567 --> 00:27:50,134
Fundamentally,
it uses static charge,
500
00:27:50,136 --> 00:27:51,402
Which is what you'd get
501
00:27:51,404 --> 00:27:53,037
If you had a balloon
and rubbed it on your jumper
502
00:27:53,039 --> 00:27:54,471
And then held it to your head.
503
00:27:54,473 --> 00:27:56,473
And that would cause your hairs
to rise up
504
00:27:56,475 --> 00:27:58,175
And be attracted to the balloon.
505
00:27:58,177 --> 00:28:00,310
But in this case,
the frame has that charge.
506
00:28:00,312 --> 00:28:02,613
And when you spray
the powdered paint,
507
00:28:02,615 --> 00:28:08,752
It adheres to the surface
in a very even, uniform way.
508
00:28:08,754 --> 00:28:12,056
Narrator: The bike components
are then heated in an oven.
509
00:28:15,361 --> 00:28:18,762
Effectively, the powder melts,
it bonds,
510
00:28:18,764 --> 00:28:23,000
And it creates a very,
very robust layer.
511
00:28:23,002 --> 00:28:24,935
Powder coating
is really important
512
00:28:24,937 --> 00:28:26,470
To the longevity of our bike.
513
00:28:28,708 --> 00:28:31,575
Narrator:
Brompton bikes don't come cheap.
514
00:28:31,577 --> 00:28:36,380
They can cost anywhere between
$1,000 and nearly $4,000,
515
00:28:36,382 --> 00:28:40,050
Depending on the specs
and customization.
516
00:28:40,052 --> 00:28:44,354
Bikes are a huge and growing
business worldwide,
517
00:28:44,356 --> 00:28:48,459
With sales around
$50 billion.
518
00:28:48,461 --> 00:28:51,729
Narrator: This year,
around 150 million new bikes
519
00:28:51,731 --> 00:28:52,930
Will be sold,
520
00:28:52,932 --> 00:28:56,266
Roughly two bikes
for every car sold in the world.
521
00:28:56,268 --> 00:28:58,335
Regardless of the high
price tag,
522
00:28:58,337 --> 00:29:01,805
Cycling enthusiasts are willing
to shell out the cash
523
00:29:01,807 --> 00:29:04,742
Because of the countless
variations to choose from.
524
00:29:04,744 --> 00:29:07,444
Be it for an off-road,
on-road, mountain bike,
525
00:29:07,446 --> 00:29:09,646
Small wheels or larger tires,
526
00:29:09,648 --> 00:29:12,216
Even the frame -- carbon,
steel, aluminum.
527
00:29:12,218 --> 00:29:15,819
The list goes on and on.
528
00:29:15,821 --> 00:29:19,523
Narrator: In its basic steel
and aluminum configuration,
529
00:29:19,525 --> 00:29:24,128
This bike weighs
almost 28 pounds.
530
00:29:24,130 --> 00:29:27,631
But the most expensive models
shed some of that weight
531
00:29:27,633 --> 00:29:31,401
By substituting titanium
for steel.
532
00:29:31,403 --> 00:29:34,705
The great thing about titanium
is that it's half the density,
533
00:29:34,707 --> 00:29:38,509
But about the same strength
as steel.
534
00:29:38,511 --> 00:29:41,879
Narrator:
Although most of the work
in this factory is done by hand,
535
00:29:41,881 --> 00:29:43,981
This specialized piece
of equipment
536
00:29:43,983 --> 00:29:46,116
Performs a vital function.
537
00:29:48,687 --> 00:29:52,756
The wheels are 13.7 inches.
538
00:29:52,758 --> 00:29:56,493
The 28 spokes which support
the rim must be tightened
539
00:29:56,495 --> 00:29:59,396
To exactly
the right degree of tension.
540
00:30:01,967 --> 00:30:06,103
This used to be done by hand,
and now what we have is a robot
541
00:30:06,105 --> 00:30:08,972
That is checking
each of those spokes,
542
00:30:08,974 --> 00:30:11,875
Checking the spoke tension,
adjusting the wheel,
543
00:30:11,877 --> 00:30:15,179
Measuring the alignment,
vertical and horizontal,
544
00:30:15,181 --> 00:30:18,248
Until we get
a perfectly aligned wheel.
545
00:30:20,519 --> 00:30:21,618
Narrator: The final assembly
546
00:30:21,620 --> 00:30:26,089
Is meticulously completed,
all by hand.
547
00:30:26,091 --> 00:30:31,395
In just one day, this factory
can produce up to 300 bikes,
548
00:30:31,397 --> 00:30:36,099
Each made based on the desires
of the consumer.
549
00:30:36,101 --> 00:30:39,102
From the frame materials
to the component options,
550
00:30:39,104 --> 00:30:41,305
Paint colors and accessories,
551
00:30:41,307 --> 00:30:47,044
There are more than 16 million
ways to customize a brompton.
552
00:30:47,046 --> 00:30:49,813
Although there are
regular upgrades,
553
00:30:49,815 --> 00:30:53,617
Brompton continues to use
the same basic design
554
00:30:53,619 --> 00:30:56,520
Developed more
than 40 years ago.
555
00:30:56,522 --> 00:30:59,656
What brompton has done is decide
they'll only make one product,
556
00:30:59,658 --> 00:31:02,826
But they'll make it
superbly well year after year.
557
00:31:02,828 --> 00:31:06,029
And because there's only one
model, or one shape essentially,
558
00:31:06,031 --> 00:31:09,366
It's instantly recognizable,
a design icon.
559
00:31:09,368 --> 00:31:11,835
And that profile
is extremely invaluable,
560
00:31:11,837 --> 00:31:16,039
Especially when you're trying
to build a premium brand.
561
00:31:16,041 --> 00:31:17,908
Narrator:
To the average cyclist,
562
00:31:17,910 --> 00:31:21,311
The brompton might seem
small and unusual,
563
00:31:21,313 --> 00:31:24,815
But what makes it special
is how different it is.
564
00:31:24,817 --> 00:31:28,752
Designed to mesh with
other modes of transportation,
565
00:31:28,754 --> 00:31:33,657
This ingenious bike is proving
to be the surprising solution
566
00:31:33,659 --> 00:31:36,059
To living in a crowded city.
567
00:31:38,163 --> 00:31:41,632
Coming up, a small electrical
components plant
568
00:31:41,634 --> 00:31:45,802
On the edge of milan
is internationally recognized
569
00:31:45,804 --> 00:31:50,374
As one of the world's most
advanced manufacturing sites.
570
00:31:50,376 --> 00:31:53,110
This is the digital revolution.
571
00:31:56,615 --> 00:32:06,523
♪♪
572
00:32:06,525 --> 00:32:08,759
Narrator:
A strong wind of disruption
573
00:32:08,761 --> 00:32:12,029
Is blowing
through global manufacturing.
574
00:32:12,031 --> 00:32:14,698
It's the fourth
industrial revolution,
575
00:32:14,700 --> 00:32:18,502
Also known as industry 4.0.
576
00:32:21,573 --> 00:32:25,776
The first industrial revolution
used water and steam
577
00:32:25,778 --> 00:32:28,712
To mechanize production.
578
00:32:28,714 --> 00:32:33,517
The second used electric power
to create mass production.
579
00:32:33,519 --> 00:32:37,554
The third used electronics
and information technology
580
00:32:37,556 --> 00:32:40,123
To automate production.
581
00:32:40,125 --> 00:32:43,393
Now a fourth industrial
revolution is building
582
00:32:43,395 --> 00:32:44,561
On the third.
583
00:32:44,563 --> 00:32:48,231
This is the digital revolution.
584
00:32:48,233 --> 00:32:50,534
Narrator: The fourth
industrial revolution
585
00:32:50,536 --> 00:32:54,438
Is quickly becoming
indispensable to modern life.
586
00:32:54,440 --> 00:32:56,974
And as a result,
it's paving the way
587
00:32:56,976 --> 00:33:00,444
For transformative changes
in the way we live
588
00:33:00,446 --> 00:33:05,082
And radically disrupting
almost every business sector.
589
00:33:05,084 --> 00:33:08,618
The world economic forum,
a powerful industry think tank,
590
00:33:08,620 --> 00:33:11,788
Has nominated 16 companies
as global leaders
591
00:33:11,790 --> 00:33:13,991
In industry 4.0 technology.
592
00:33:13,993 --> 00:33:16,460
So among the really big names
that you might expect to see,
593
00:33:16,462 --> 00:33:19,896
Such as procter & gamble,
siemens, and bmw,
594
00:33:19,898 --> 00:33:23,567
There's one unlikely company
on the list.
595
00:33:23,569 --> 00:33:27,037
Narrator: This is rold,
596
00:33:27,039 --> 00:33:30,173
A milan-based electronic
component manufacturer
597
00:33:30,175 --> 00:33:34,544
That employs just under
250 people.
598
00:33:34,546 --> 00:33:37,047
Founded in 1963,
599
00:33:37,049 --> 00:33:40,283
Rold has carved itself out
a lucrative niche
600
00:33:40,285 --> 00:33:42,786
As one of europe's
largest producer
601
00:33:42,788 --> 00:33:47,357
Of door locks
for washing machines.
602
00:33:47,359 --> 00:33:50,160
And the secret to this
company's success
603
00:33:50,162 --> 00:33:53,063
Is how rold
makes their products.
604
00:33:55,034 --> 00:33:57,634
People are taking notice
of this smallish company
605
00:33:57,636 --> 00:33:59,136
Because recently
they were nominated
606
00:33:59,138 --> 00:34:00,470
As part of a global network
607
00:34:00,472 --> 00:34:03,306
Of so-called
manufacturing lighthouses.
608
00:34:03,308 --> 00:34:06,710
The members have successfully
adopted 4.0 technologies
609
00:34:06,712 --> 00:34:08,545
And have opened their doors
to share their knowledge
610
00:34:08,547 --> 00:34:10,981
With other businesses.
611
00:34:10,983 --> 00:34:13,216
Narrator: Leading this small
family-run business
612
00:34:13,218 --> 00:34:15,919
Into a technological
brave new world,
613
00:34:15,921 --> 00:34:19,489
Is c.E.O. Laura rochitelli.
614
00:34:40,846 --> 00:34:45,816
Today, the facility is
manufacturing a lock component.
615
00:34:45,818 --> 00:34:48,151
The production process starts
616
00:34:48,153 --> 00:34:51,121
In rold's
raw-materials warehouse.
617
00:35:05,938 --> 00:35:08,872
From the materials' warehouse,
the polymer pellets
618
00:35:08,874 --> 00:35:13,977
Are transported through a series
of pipes to the molding room.
619
00:35:13,979 --> 00:35:16,646
Machines here produce
the plastic components
620
00:35:16,648 --> 00:35:18,281
Of the locking units.
621
00:35:20,319 --> 00:35:23,820
Polymer is pumped into
the machine as raw pellets...
622
00:35:26,024 --> 00:35:30,594
...And comes out as molded
plastic casings
623
00:35:30,596 --> 00:35:33,697
Through a process
called injection molding.
624
00:35:38,403 --> 00:35:40,437
Injection molding is
essentially a process
625
00:35:40,439 --> 00:35:43,974
Of making objects
by heating up a material,
626
00:35:43,976 --> 00:35:47,177
Squirting it into
the cavity of a mold,
627
00:35:47,179 --> 00:35:50,413
That object then solidifying
inside that mold
628
00:35:50,415 --> 00:35:53,016
And then opening up
and you have your thing.
629
00:35:53,018 --> 00:35:55,886
But that material, that could be
all sorts of things --
630
00:35:55,888 --> 00:35:57,187
Glass, plastic, metal --
631
00:35:57,189 --> 00:35:59,122
Anything that could be
melted down.
632
00:35:59,124 --> 00:36:03,226
Even cakes
can be injection-molded.
633
00:36:03,228 --> 00:36:05,862
Narrator: Every single machine
in this factory
634
00:36:05,864 --> 00:36:08,131
Is connected
to a digital network
635
00:36:08,133 --> 00:36:12,035
That tracks every aspect
of product performance.
636
00:36:36,195 --> 00:36:37,861
Digital data enables operators
637
00:36:37,863 --> 00:36:39,829
To monitor
production performance
638
00:36:39,831 --> 00:36:43,266
Of individual machines
in real time.
639
00:36:43,268 --> 00:36:45,802
The system is constantly
troubleshooting,
640
00:36:45,804 --> 00:36:47,971
Spotting any potential problems
641
00:36:47,973 --> 00:36:50,540
Before they can
affect production.
642
00:37:07,859 --> 00:37:09,593
And it's not just the machines
643
00:37:09,595 --> 00:37:13,496
That are digitally connected
in this super factory.
644
00:37:13,498 --> 00:37:15,565
This level of digitization
645
00:37:15,567 --> 00:37:18,268
Can have a profound effect
on efficiency.
646
00:37:24,476 --> 00:37:28,178
Narrator: For over 50 years,
rold has applied innovation
647
00:37:28,180 --> 00:37:31,381
And quality research
to manufacture appliances
648
00:37:31,383 --> 00:37:34,884
That have impacted
our everyday way of life.
649
00:37:34,886 --> 00:37:38,622
The first rold door locks
date back to the 1970s
650
00:37:38,624 --> 00:37:41,458
When the company was among
the first manufacturers
651
00:37:41,460 --> 00:37:44,995
Offering a door-locking system
that was soon to be required
652
00:37:44,997 --> 00:37:47,130
On all washing machines.
653
00:37:49,534 --> 00:37:54,404
Today, just like this
component, rold has evolved,
654
00:37:54,406 --> 00:37:59,175
Enhancing their appliances
in our new digitized world.
655
00:37:59,177 --> 00:38:01,144
Back on the assembly line,
656
00:38:01,146 --> 00:38:04,381
Real-time data coming
from the production process
657
00:38:04,383 --> 00:38:09,285
Can be accessed either
in the plant or remotely.
658
00:38:09,287 --> 00:38:12,055
If something breaks
or slows down,
659
00:38:12,057 --> 00:38:16,326
Engineers are updated
instantly via smart device.
660
00:38:17,796 --> 00:38:19,262
Even though the new technology
661
00:38:19,264 --> 00:38:22,165
Tracks every second
of each machine's output,
662
00:38:22,167 --> 00:38:24,934
Plastic components
are frequently quality-checked
663
00:38:24,936 --> 00:38:27,704
Using the same digital system.
664
00:38:40,352 --> 00:38:42,752
The system identifies
a component,
665
00:38:42,754 --> 00:38:46,156
Uploads the design blueprint
and automatically checks
666
00:38:46,158 --> 00:38:50,026
The part for quality against the
digital tech spec.
667
00:39:04,343 --> 00:39:06,343
While the plastic components
are produced
668
00:39:06,345 --> 00:39:08,244
By injection molding,
669
00:39:08,246 --> 00:39:11,715
The metal fixings are made
by press punching.
670
00:39:31,970 --> 00:39:34,838
The output of the metal
components' presses
671
00:39:34,840 --> 00:39:38,141
Is constantly monitored
digitally by the workforce.
672
00:39:40,045 --> 00:39:42,679
If there's any issue
threatening output,
673
00:39:42,681 --> 00:39:45,115
The team can instantly identify
674
00:39:45,117 --> 00:39:47,951
And solve the problem
immediately.
675
00:39:47,953 --> 00:39:51,454
This level of digitization
can have a profound effect
676
00:39:51,456 --> 00:39:55,258
On the efficiency and day-to-day
running of companies like rold.
677
00:39:55,260 --> 00:39:58,428
Knowing exactly what's happening
at any points in the enterprise
678
00:39:58,430 --> 00:40:01,698
Has a huge transformative effect
on efficiency
679
00:40:01,700 --> 00:40:03,433
And company productivity.
680
00:40:05,771 --> 00:40:08,905
Narrator: Now the plastic and
metal components come together
681
00:40:08,907 --> 00:40:10,607
For final assembly.
682
00:40:13,111 --> 00:40:15,044
These machines can produce
683
00:40:15,046 --> 00:40:17,814
2,000 door-lock components
an hour.
684
00:40:19,718 --> 00:40:22,886
Each item
is given its own unique I.D.
685
00:40:22,888 --> 00:40:26,289
And can be instantly tracked,
logged, and checked
686
00:40:26,291 --> 00:40:28,391
Before they're dispatched.
687
00:40:30,695 --> 00:40:32,362
Down on the factory floor,
688
00:40:32,364 --> 00:40:35,965
The finished units are put
into a machine for inspection.
689
00:41:03,762 --> 00:41:06,729
In manufacturing terms,
rold is what's known as an sme,
690
00:41:06,731 --> 00:41:08,932
A small or medium enterprise.
691
00:41:08,934 --> 00:41:11,668
What they've done proves that
4.0 technologies aren't just
692
00:41:11,670 --> 00:41:15,338
The preserve of rich,
huge, wealthy corporations.
693
00:41:15,340 --> 00:41:16,606
They've basically taken
694
00:41:16,608 --> 00:41:18,641
Off-the-shelf software
and hardware,
695
00:41:18,643 --> 00:41:21,177
Collaborated with universities
and tech providers
696
00:41:21,179 --> 00:41:23,079
To create a system
that works for them.
697
00:41:23,081 --> 00:41:26,850
And to get it all started,
they hired three programmers.
698
00:41:42,000 --> 00:41:45,068
Rold clearly demonstrates
the opportunities offered
699
00:41:45,070 --> 00:41:47,604
By this new industrial
revolution,
700
00:41:47,606 --> 00:41:51,140
And it also proves
you can be a small company
701
00:41:51,142 --> 00:41:55,278
But still make the grade
as a super factory.