Super Factories (2020–…): Season 1, Episode 5 - Maserati Mega Plant - full transcript

Narrator: THE SECRETS OF A
WORLD-FAMOUS SNACK ARE REVEALED.

ROBOTS AND HUMANS
ARE WORKING IN TANDEM

TO CREATE THIS SOPHISTICATED
LUXURY SPORTS CAR.

MODERN TECHNOLOGY
IS BRINGING CHARACTERS

FROM A POPULAR
ANIME TV SERIES TO LIFE.

AND THIS EUROPEAN MANUFACTURER
IS FLUSHING OUT THE COMPETITION

BY PUSHING THE BOUNDARIES
OF DESIGN AND ENGINEERING.

THESE GROUNDBREAKING INNOVATIONS
ARE ALL TAKING PLACE

INSIDE SOME OF THE MOST
INCREDIBLE FACTORIES

ON THE PLANET.

LOCATED IN PERRY, GEORGIA,
IS THE FRITO-LAY FACTORY,



THE WORLD'S LEADING
SUPPLIER OF POTATO CHIPS.

IT'S HERE WHERE THE COMPANY'S
FAMOUS CHIP BRANDS, DORITOS,

CHEETOS, FRITOS, AND LAYS

ARE PRODUCED IN OVER
160 FLAVOR VARIETIES.

Russell: POTATO CHIPS ARE MASSIVE,
AND LAYS ARE A BIG PLAYER IN THIS.

LAYS HAVE BEEN AROUND
FOR ABOUT 80 YEARS.

Narrator: TODAY, FRITO-LAYS IS
ONE OF THE MOST RECOGNIZABLE

CHIP BRANDS IN THE WORLD,

CONTROLLING 35%
OF THE SNACK CHIP MARKET.

BUT THIS BUSINESS GREW
FROM VERY HUMBLE BEGINNINGS.

SO WHO INVENTED THE POTATO CHIP?
GOOD QUESTION.

SOME SAY IT WAS A CHEF
NAMED GEORGE CRUM

IN NEW YORK STATE IN THE 1850s.

SO WHAT WE DO KNOW
IS THAT HERMAN LAY STARTED



PEDALING CHIPS OUT OF HIS
MODEL A FORD IN 1931.

SOON HE HAD HIS FIRST FACTORY,
AND THE REST IS HISTORY.

Narrator: FOR MORE
THAN 20 YEARS,

THE PERRY FACILITY HAS BEEN

A MAJOR PART
OF THE COMMUNITY

IN THIS PART OF THE STATE.

AT NEARLY 990,000 SQUARE FEET,

THE FACTORY SITS
ON 1,500 ACRES OF LAND.

IT'S ALSO THE FIRST FACILITY
IN GEORGIA TO BE AWARDED

A LEAD CERTIFICATION,

RECOGNIZING IT AS AN
ENVIRONMENTALLY FRIENDLY SITE.

BUT THE KEY TO
THIS FACTORY'S SUCCESS

IS NOT ONLY ITS UNIQUE FACILITY,

IT'S ALSO WHAT'S BEING
MANUFACTURED INSIDE.

AT FRITO-LAY,
QUALITY BEGINS AT THE FARM,

THIS FACTORY IMPORTS POTATOES
FROM 120 FARMS

ACROSS 25 DIFFERENT STATES.

JUST LIKE THEIR
BUILDING STANDARDS,

QUALITY CONTINUES THROUGHOUT
THE MANUFACTURING PROCESS

THROUGH VITAL
VISUAL INSPECTIONS,

Maxwell: ALL OUR POTATOES
GET A QUALITY CHECK.

WE'RE LOOKING AT APPEARANCE.
WE'RE LOOKING AT SIZE.

COLOR, TEMPERATURE,
AND WE HAVE SPECIFICATIONS

FOR ALL OF THOSE THINGS,

Narrator: ONCE THEY
PASS INSPECTION,

THE POTATOES ARE WASHED
AND PEELED

USING SPECIALIZED EQUIPMENT.

HERMAN LAY DEVELOPED
THE MECHANICAL POTATO PEELER

JUST UNDER 100 YEARS AGO,

THAT WAS A GAME CHANGER.

LAYS HAVE NEVER LOOKED BACK.

Narrator:
ONCE THE POTATOES ARE CLEANED,

THEY MOVE DOWN A BELT
TO A SLICING MACHINE.

THE MACHINE'S RAZOR-SHARP BLADES
CUT THE POTATOES INTO A VARIETY

OF DIFFERENT THICKNESSES
AND SHAPES.

INSIDE THE SLICING MACHINE,
THE CENTRIFUGAL FORCE CREATED

BY THE SPINNING DRUMS THROWS
THE POTATOES AGAINST THE BLADES,

RAPIDLY SLICING THEM
INTO VERY THIN PIECES.

NEXT, THE POTATO SLICES

ARE WASHED TO REMOVE
ANY REMAINING STARCH.

THEN DRIED TO REDUCE MOISTURE.

NOW THE CHIPS
ARE READY TO BE FRIED.

THE CHIPS ARE FRIED
IN CANOLA OIL

IN A TEMP ABOUT
350 DEGREES.

AND THAT PROCESS, AS IT COMES,
IT TAKES ABOUT THREE MINUTES

AS IT GOES FROM THE SLICING
PROCESS TO THE FRYING PROCESS.

AS THEY GO THROUGH
THE FRYING PROCESS,

THIS WOULD BE THE
FINISHED PRODUCT.

Narrator: AFTER FRYING,
THE CHIPS ARE SALTED,

FLAVORED, AND FED INTO LARGE
SORTING CONTAINERS.

EACH CONTAINER AUTOMATICALLY
MEASURES OUT THE CHIPS

INTO HALF POUND PORTIONS.

THEN THEY'RE DISTRIBUTED
INTO INDIVIDUAL PACKAGES.

AND FRITO-LAY'S SECRET TO
KEEPING THE CHIPS FRESH

CAN BE FOUND INSIDE THE BAG.

NITROGEN IS PUMPED INTO THE BAGS
FOR TWO REASONS.

IT REDUCES THE AMOUNT
OF OXYGEN IN THE BAGS.

AND THAT OXYGEN
CAN INCREASE FOOD DECAY.

AND THEN THE SECOND REASON
IS IT CREATES A CUSHION.

AND THIS MEANS THAT THE CRISPS
AREN'T SMASHED TO SMITHEREENS

BY THE TIME THEY REACH YOU.

Narrator: BACK
ON THE ASSEMBLY LINE,

A TECHNICIAN THOROUGHLY INSPECTS
THE OUTSIDE OF EACH BAG.

I'M DOING MY QUALITY
CHECK IN THE MORNING,

I'M GOING TO CHECK OUT
MY BACK SEAL,

MAKE SURE IT'S SOLID.

THE SEAL'S INTEGRITY
IS GOOD,

THAT I HAVE A PRICE
AND DATE ON HERE,

AND THAT IT'S LEGIBLE.

AND ALSO THAT THE GRAPHICS
ARE NOT TWISTED

OR ANYTHING LIKE THAT.

Narrator: ONCE THE BAGS ARE
SEALED, THEY'RE TRANSPORTED

TO THE COMPANY'S 700,000
SQUARE FOOT DISTRIBUTION CENTER.

HERE, MORE THAN 1,250
OPERATORS WORK

WITH SPECIAL PURPOSE EQUIPMENT
TO STOCK AND PROCESS ORDERS

FOR RETAILERS
ALL OVER THE COUNTRY.

SO THIS WEEK ALONE,

FRITO-LAY NATIONALLY WILL MAKE
HALF A MILLION SERVICE CALLS

AND WILL MAKE THOSE SERVICE
CALLS OVER 15,000 ROUTES.

MUCH OF THAT PRODUCT WILL GET
INTO THE MARKETPLACE

ON OVER THE ROAD VEHICLES
AND OUR ENTIRE FLEET OF ASSETS

IS 23,000 IN FRITO-LAY
IN THE UNITED STATES.

THE COMPANY HAS ONE OF THE
LARGEST PRIVATE VEHICLE FLEETS

IN THE U.S.,
WHICH IT USES TO TRANSPORT

THE GOODS TO POINTS OF SALE...
GROCERY STORES AND SUPERMARKETS.

Narrator: POTATO CHIPS REPRESENT
ONE OF THE MOST POPULAR SNACKS

CONSUMED ACROSS THE GLOBE.

WITH A PROJECTED MARKET VALUE

SET TO REACH $35 BILLION
BY 2024,

THERE'S NO QUESTION
THAT THIS SALTY SNACK

IS IN HIGH DEMAND IN THE U.S.

AND RECENT STUDIES SUGGEST THE
DEMAND FROM EMERGING ECONOMIES

IS ALSO ON THE RISE.

UP UNTIL NOW, POTATO CHIPS
HAVE MAINLY BEEN CONSUMED

IN THE RICHER COUNTRIES,

THE SO-CALLED DEVELOPED
WORLD OF THE WEST.

BUT THAT IS LIKELY TO CHANGE
IN THE FUTURE

AS DEVELOPING COUNTRIES

ARE SEEN AS BEING
THE NEXT BIG GROWTH AREA.

Narrator:
FOR OVER 75 YEARS,

FRITO-LAY HAS BEEN
MANUFACTURING SATISFYING SNACKS

TO PEOPLE AND RETAILERS
AROUND THE WORLD.

TODAY, THE PERRY FACILITY
PRODUCES OVER 1.7 BILLION

BAGS OF CHIPS A YEAR.

THE WORKFORCE IS DEDICATED TO
PRODUCING HIGH-QUALITY SNACKS,

AND IT'S THEIR ABILITY TO MIX
PRODUCTIVITY WITH MODERNITY

THAT MAKES THIS FACTORY
A SUPER FACTORY.

COMING UP, NEW TECHNOLOGY
IS COMBINED

WITH ITALIAN CRAFTSMANSHIP

TO PRODUCE THE WORLD'S
MOST DISTINGUISHED SPORTS CAR.

ONE OF THE KEY POINTS FOR US
IS LUXURY, BECAUSE LUXURY

MEANS THE HIGHEST STANDARDS
OF THE MANUFACTURING.

Narrator:
AND LATER, IN JAPAN,

THIS SUPER FACTORY
IS OPTIMIZING PRODUCTIVITY

BY UTILIZING THE LATEST
AUTOMATED TECHNOLOGIES

TO CREATE TOYS FOR
ANIME FANS ALL OVER THE WORLD.

♪♪

♪♪

Narrator: SURROUNDED BY
THE BUSTLING CITY STREETS

OF TURIN, ITALY,

IS A FACTORY PRODUCING
A LEGENDARY SPORTS CAR.

FOR OVER A CENTURY,
MASERATI HAS BEEN MANUFACTURING

BEAUTIFULLY DESIGNED VEHICLES

EQUIPPED WITH A HIGH
PERFORMANCE RACING ENGINE.

NOW IN ITS SIXTH GENERATION,
THE QUATTROPORTE

IS MASERATI'S
TOP-SELLING VEHICLE

AND IS ONE OF THE MOST
LUXURIOUS CARS IN PRODUCTION

ANYWHERE IN THE WORLD.

ONE OF THE KEY POINTS FOR US
IS LUXURY,

BECAUSE LUXURY MEANS THE
HIGHEST STANDARDS OF MATERIALS,

HIGHEST STANDARDS
OF THE MANUFACTURING.

Narrator:
LIKE ITS PREDECESSORS.

THE QUATTROPORTE'S DISTINCTIVE
SLEEK DESIGN,

HANDCRAFTED INTERIORS,
AND POWERFUL RACING ENGINE

ARE WHAT MAKES IT A CUT ABOVE
ITS LUXURY SEDAN COMPETITORS.

THE MASERATI BROTHERS
SET UP A WORKSHOP

FOR EARLY RACING CARS IN 1914,

AND THEY DOMINATED RACETRACKS
FOR THE NEXT 50 YEARS.

IN 1963, THEY UNVEILED
THE QUATTROPORTE SPORTS SEDAN,

THE FASTEST FOUR-DOOR CAR
IN THE WORLD.

Narrator: THE QUATTROPORTE
IS DESIGNED, PRODUCED,

AND ASSEMBLED HERE
AT THE TURIN MANUFACTURING HUB

LOCATED IN NORTHERN ITALY,

BUT IT'S NOT THE ONLY
VEHICLE MANUFACTURED

AT THIS MASSIVE FACILITY.

IN 1993, FIAT CHRYSLER
ACQUIRED MASERATI

AND FOUR YEARS LATER
TURNED MANAGEMENT OF MASERATI

OVER TO FERRARI.

A LOT OF THE FAMOUS
MANUFACTURERS, ROLLS-ROYCE,

DAIMLER, AND MANY ARE ACTUALLY
OWNED BY CONGLOMERATES,

AND THAT'S BECAUSE
OF ECONOMIES OF SCALE.

SO MASERATI ARE OWNED
BY FIAT CHRYSLER,

AS ARE ALFA ROMEO AND FERRARI.

Narrator: THIS CONSOLIDATION
MEANT THAT ALL THREE BRANDS

WOULD BE PRODUCED
WITH THE SAME TECHNOLOGY

AND THAT MASERATI SEDANS
WOULD NOW BE BUILT

WITH FERRARI RACING ENGINES.

TODAY, MASERATI

IS THE DESIGNATED
LUXURY BRAND OF FIAT.

EVERY SINGLE MASERATI
IS A WORK OF ART MADE BY PEOPLE.

THIS SUCH CRAFT WORK.

Narrator: TO UPHOLD THE
STANDARDS OF THE MASERATI BRAND,

THE ASSEMBLY PROCESS IS DESIGNED
TO ELEVATE MODERN TECHNOLOGIES

WITH DECADES
OF ITALIAN CRAFTSMANSHIP.

IN MY OPINION, HERE WE HAVE
THE PERFECT MARRIAGE

BETWEEN MEN AND AUTOMATION

BECAUSE THERE ARE SOMETHING
THAT THE ROBOT CANNOT GIVE.

THE ATTENTION TO
EACH SINGLE DETAIL,

AND ONLY A HUMAN BEING
CAN DO THAT.

Narrator: HERE, ASSEMBLY STATIONS
ARE ERGONOMICALLY DESIGNED

TO ENSURE EVERY PROCESS

IS EASILY ACCESSIBLE
FOR THE WORKFORCE.

SO A LOT OF THOUGHT HAS GONE
INTO DESIGNING

ERGONOMIC ASSEMBLY LINES

DESIGNED AND STRUCTURED SO THAT
WORKERS DON'T STRETCH THEMSELVES

OR TWIST TOO MUCH AND INCUR
REPETITIVE STRAIN INJURY.

THE ULTIMATE AMBITION
IS TO AVOID PEOPLE

HURTING THEMSELVES AT WORK.

Narrator:
MAKING A QUATTROPORTE

BEGINS WITH THE CHASSIS
ASSEMBLY.

THE CHASSIS IS BUILT AROUND
A RIGID AND SECURE

STEEL SAFETY STOW

MADE WITH STEEL
AND ALUMINUM ALLOYS.

THE FRONT OF THE CHASSIS
IS BUILT AROUND

AN ALUMINUM CASTING,

WHILE THE BACK IS MADE
FROM ROLLED STEEL.

EVERY SINGLE PART OF HOW
A VEHICLE PERFORMS

CAN BE ATTRIBUTED
TO ITS WEIGHT DISTRIBUTION.

A CAR THAT IS LIGHTER IN WEIGHT
IS ACTUALLY MORE FUEL EFFICIENT.

MAGNESIUM IS PARTICULARLY
GOOD AT THIS.

IT'S 36% LIGHTER
THAN ALUMINUM

AND A WHOPPING 78%
LIGHTER THAN STEEL.

LESS FUEL BEING USED
MEANS LESS EMISSIONS.

Narrator: AS SOON AS THE CHASSIS
ARRIVES ON THE PRODUCTION LINE,

THE TEAM GETS TO WORK
ASSEMBLING A CAR AROUND THIS

ONE ESSENTIAL BUILDING BLOCK.

THE SECRET TO PAINTING
A MASERATI

IS IN THIS TECHNOLOGICALLY
ADVANCED PROCESS.

ONCE ASSEMBLED, THE BODY
IS COATED IN A FLUID

THAT PROTECTS IT FROM
CORROSION AND OXIDIZATION.

NEXT, THE FRAMEWORK MOVES DOWN
THE ASSEMBLY LINE

TOWARDS A DIP TANK.

SUSPENDED BY AN ELECTRICALLY
CHARGED CHAIN,

THE BODY IS SUBMERGED
INTO A PAINT SOLID MIXTURE

MADE UP OF SOLVENTS,
RESIN, AND WATER.

AS THE BODY MOVES
INTO THE FLUID,

THE PAINT IS DEPOSITED ONTO THE
CAR THROUGH AN ELECTRIC CURRENT.

THIS PROCESS
IS CALLED CATAPHORESIS.

AFTER IT'S TREATED,
THE BODY IS HEATED

IN A GIANT 130-FOOT OVEN
AT 375 DEGREES FOR 30 MINUTES.

THE EXTREME HEAT
SOLIDIFIES THE PAINT

TO ENSURE MAXIMUM PERFORMANCE.

ONCE THE PROTECTIVE LAYER
HAS HARDENED,

ALL REMAINING CONTAMINANTS
ARE REMOVED

USING A NONTRADITIONAL BRUSH
MADE OF OSTRICH FEATHERS.

YOU MIGHT WONDER WHY WE USE
OSTRICH FEATHERS

WELL, OSTRICH FEATHERS
HAVE AN INNATE STATIC CHARGE

NOT FOUND IN OTHER FEATHERS,
WHICH MAKES THEM REMARKABLY GOOD

AT PICKING UP VERY FINE
PARTICLES OF DUST.

Narrator: NOW IT'S READY
TO BE PAINTED.

FIRST, AIR PAINT ATOMIZERS
APPLY A CODE OF PRIME.

IT TAKES JUST A FEW MINUTES
TO PAINT A TYPICAL MASERATI CAR.

AS THE CAR MOVES DOWN
THE ASSEMBLY LINE,

A TOP COAT OF PAINT IS APPLIED.

AN AIR PAINT ATOMIZER
USES AERODYNAMIC FORCE

TO PUSH THE PAINT
ONTO THE VEHICLE.

THE PAINT PARTICLES
SCATTER AROUND

AS THEY BOUNCE OFF THE SURFACE
AND INTO THE AIR.

THE RESULT, A PERFECTLY SMOOTH
COAT OF PAINT.

NOW A LAYER OF CLEAR LACQUER
IS APPLIED

TO GIVE THE CAR
AN EXTRA GLOSSY SHEEN.

BEFORE IT'S DELIVERED
TO THE ASSEMBLY FLOOR,

TECHNICIANS INSPECT THE FINISH
FOR ANY IMPERFECTIONS.

THE VALUES LEARNED
OUT ON THE RACETRACK

ARE APPLIED
ON THE FACTORY FLOOR.

HERE, AN EMPTY PAINTED SHELL
WILL BECOME A MASERATI.

THIS IS THE FIRST OF 24
ASSEMBLY STATIONS,

WHERE THE PURSUIT OF LUXURY
MIXES WITH EFFICIENCY.

EACH CAR SPENDS NO LONGER

THAN 37 MINUTES
AT EACH STATION.

FROM THE INTERIOR FINISH
TO THE LEATHER AND PAINT WORK,

EVERY QUATTROPORTE
BUILT IN THIS FACTORY

IS CUSTOMIZED BASED
ON THE REQUESTS OF THE CONSUMER.

THIS IS WHAT GIVES MASERATI
ITS EXCLUSIVE EDGE.

Meccia:
IN TERMS OF CUSTOMIZATION,

I WOULD SAY 100%
CUSTOMIZABLE.

MORE THAN 1.5 TRILLION
POSSIBLE DIFFERENT COMBINATION.

THAT, OF COURSE, IS TRANSFORMED
FROM A COMMERCIAL STANDPOINT,

NOT SO EASY TO MANAGE
IN TERMS OF MANUFACTURING,

Narrator: BUT THERE'S STILL MORE
TO BE ASSEMBLED

BEFORE THIS LUXURY VEHICLE
IS READY TO HIT THE ROAD.

AND TO DO SO,
IT'LL TAKE BOTH MAN AND MACHINE

WORKING TOGETHER TO EXECUTE
EACH STEP TO PERFECTION.

♪♪

Narrator: LOCATED IN TURIN,
ITALY, IS THE MASERATI FACTORY,

THE WORLD'S LEADING MANUFACTURER
OF LUXURY SPORTS CARS.

FOR OVER A CENTURY,
THIS LEGENDARY COMPANY

HAS BEEN AT THE FOREFRONT
OF THE INDUSTRY,

PRODUCING
HIGH-PERFORMANCE VEHICLES

BUILT WITH RACING ENGINES.

ON THE ASSEMBLY FLOOR,
TECHNICIANS GUIDE THE DASHBOARD

THROUGH A MECHANICAL
ASSEMBLY PROCESS,

BUT THIS IS
NO ORDINARY DASHBOARD.

IT'S UPHOLSTERED IN FINE LEATHER
AND MADE FROM MAGNESIUM,

MAKING IT BOTH STRONG
AND LIGHTWEIGHT.

ONCE THE DASHBOARD IS ASSEMBLED,
TECHNICIANS CONNECT THE WIRING.

IT'S ESSENTIAL THAT THIS STEP
IS ALL DONE BY HAND.

NEXT, A MACHINE INSTALLS
THE WINDSHIELD.

SUCTION CUPS LIFT THE GLASS
BEFORE APPLYING A SEALANT,

LASER SENSORS MEASURE
THE OPENING IN THE BODY

AND PRECISELY SECURE IT
INTO PLACE.

THEN THE CAR MOVES FROM THE TRIM
LINE ONTO THE CHASSIS LINE.

NOW THE HEART OF THE CAR
IS INSTALLED.

THIS INCREDIBLY POWERFUL
350 HORSEPOWER FERRARI ENGINE

CAN GO FROM ZERO
TO 60 MILES PER HOUR

IN JUST 5.5 SECONDS.

NEXT, THE BODY OF THE CAR
AND ENGINE ARE FITTED TOGETHER.

FIRST, A TEAM
BUILDS THE DRIVETRAIN,

WHICH IS MADE UP
OF THE ENGINE, GEARBOX,

SHOCK ABSORBERS, FRONT EXHAUST
SYSTEM, AND BRAKES.

ALL COMPONENTS ARE PLACED
INTO AN ASSEMBLY JIG

THAT TRANSPORTS
THE MECHANICAL ELEMENTS

DIRECTLY UNDER THE BODY.

THE DRIVETRAIN IS THEN
RAISED INTO POSITION

SO THE TWO SECTIONS
CAN BE SECURED WITH BOLTS.

NOW, ANOTHER TEAM
INSTALLS THE HEADLIGHTS,

WHEELS, TIRES, AND SEATS.

THE FINAL STAGE CONSISTS OF AN
INSPECTION AND A STABILITY TEST.

THEN IT'S OFF TO THE CUSTOMER
AND OUT ONTO THE OPEN ROAD.

Meccia: THE LEGEND AND THE BRAND
IMAGE OF MASERATI BEGAN

WITH THE WORLD OF RACES, SO MORE
THAN ONE CENTURY OF HISTORY.

AND THIS IS WHY
MASERATI IS SO VALUABLE.

Narrator: MASERATI IS OFTEN
REFERRED TO AS ONE OF THE TOP

LUXURY CAR BRANDS IN HISTORY,
AND THE SKILL AND SOPHISTICATION

FOUND INSIDE
THEIR PRODUCTION FACILITY

MAKE IT ONE OF THE WORLD'S MOST
SPECTACULAR SUPER FACTORIES.

COMING UP, IN JAPAN, CHARACTERS
FROM A BELOVED ANIME SERIES

ARE BEING MANUFACTURED
FOR THE MASSES.

THE KITS ARE BASED ON A 1970s
TV SERIES

CALLED "GUNDAM."

MODEL MAKERS AND
ANIME FANS IN JAPAN

AND OTHER PARTS OF ASIA
ARE CRAZY ABOUT THEM.

Narrator: AND LATER, THIS
FACTORY PRODUCES THE ALMIGHTY

PORCELAIN THRONE

USING A VERY UNIQUE MATERIAL.

IT LOOKS LIKE CHOCOLATE,
BUT I WOULDN'T TASTE IT.

♪♪

Narrator: IN TOKYO, THE WORLD'S
LARGEST HUMANOID ROBOT IS ON DISPLAY,

MODELED AFTER
THE FICTIONAL ROBOTS

FROM THE 1970s SCI-FI
FRANCHISE "GUNDAM,"

THIS 65-FOOT-TALL REPLICA
HAS BECOME POPULAR

WITH ANIME FANS
FROM AROUND THE GLOBE.

BUT IT'S NOT JUST
THE GIANT ROBOT STATUE

THAT'S DRAWING IN THE CROWDS.

FOR A MORE INTERACTIVE
EXPERIENCE,

FANS HEAD TO THE BANDAI
HOBBY CENTER

AND MODELING SUPER FACTORY.

SINCE 1980,

THIS MANUFACTURING FACILITY
HAS COMBINED 3-D DESIGN,

CUTTING EDGE TECHNOLOGY,
AND SKILLED CRAFTSMANSHIP

TO PRODUCE GUNDAM
PLASTIC MODELING KITS.

THE KITS ARE BASED ON A 1970s
TV SERIES CALLED "GUNDAM."

MODEL MAKERS AND ANIME FANS
IN JAPAN

AND OTHER PARTS OF ASIA
ARE CRAZY ABOUT THEM.

BANDAI IS NOW THE SECOND BIGGEST
TOY COMPANY IN THE WORLD,

VALUED AT $9.6 BILLION.

Narrator: GUNDAM TOYS ARE
CONSTRUCTED FROM PLASTIC FRAMES

THAT CONTAIN INDIVIDUAL PIECES
CALLED RUNNERS,

THE INDIVIDUAL PIECES
ARE ALL NUMBERED,

SO THE MODEL KITS
CAN BE EASILY ASSEMBLED.

THE FIRST STEP
IS DESIGNING A CHARACTER.

TODAY, IT'S
THE GUNDAM RED FLAME.

♪♪

THE DESIGN IS BROKEN DOWN
INTO INDIVIDUAL PARTS

THAT MAKE UP THE MODEL KITS.

BANDAI USES 3-D PRINTING
TO CREATE MODELS

FOR OVER 400 DIFFERENT DESIGNS.

THIS STATE-OF-THE-ART TECHNOLOGY

HAS COMPLETELY TRANSFORMED
THE TOY INDUSTRY.

3-D PRINTING, MORE COMMONLY
TODAY KNOWN AS

ADDITIVE MANUFACTURING,

ACTUALLY BEGAN IN 1986.

THE FIRST PRODUCT TO BE PRINTED

WAS A SMALL PLASTIC CUP
USED FOR HOLDING EYEWASH.

TODAY, 3-D PRINTERS
USE A RANGE OF MATERIALS

TO PRODUCE THEIR PRODUCTS,
FROM RESINS AND PLASTICS

TO CERAMICS
AND EVEN ADVANCED METALS.

THE HUGE ADVANTAGE
IN 3-D PRINTING

FOR INVENTORS
AND ENGINEERS

IS THEY CAN MAKE A ONE-OFF,
A SINGLE PRODUCT

THAT WORKS WITHOUT
THE VAST CAPITAL EQUIPMENT

INVESTMENTS OF
A WHOLE PRODUCTION LINE.

Narrator: NEXT, TECHNICIANS
CONFIGURE THE LAYOUT

FOR THE MOLDS BY ARRANGING
THE PARTS INTO KITS.

ONCE THE LAYOUT IS FINALIZED
AND THE 3-D DATA IS COMPLETED,

THE DESIGN IS SENT
TO THE MOLDING TEAM.

THROUGH A FABRICATION PROCESS

CALLED ELECTRICAL
DISCHARGE MACHINING,

A LASER CUTS
THROUGH A METAL BLOCK,

FORMING IT INTO VARIOUS SHAPES.

ELECTRICAL DISCHARGE MACHINING
IS A WAY OF CUTTING METAL

USING ELECTRICITY.

MATERIAL IS REMOVED
FROM A METAL BLOCK

BY A SERIES OF RAPIDLY
RECURRING CURRENT DISCHARGES.

THE TWO CONDUCTORS
ARE SEPARATED BY A LIQUID

AND THE RESULTING SPARKS
ERODE THE METAL,

A BIT LIKE CREATING
MINI LIGHTNING BOLTS

THAT CREATE INTENSE HEAT WHICH
FORM THE DESIRED FINAL SHAPE.

Narrator: NOW THE CONCAVE
AND CONVEX METAL SHAPES

ARE CARVED OUT OF THE SOLID
BLOCK, THEN TRIMMED.

THIS STEP CAN ONLY
BE DONE BY HAND.

TECHNICIANS TRIM THE CORNERS
AND MAKE GROOVES.

THE METAL SHAPES ARE CONFIGURED

INTO WHAT WILL BECOME
A PLASTIC FRAME.

IF ANY MISTAKE OCCURS
DURING SHAPING,

THE ENTIRE MOLD
HAS TO BE THROWN OUT.

A CRANE TRANSPORTS THE MOLDS
TO AN INJECTION MOLDING MACHINE.

HERE, THE MOLDS ARE LOADED
AND CLAMPED WITH ENOUGH FORCE

TO KEEP THEM SECURELY IN PLACE.

THEN POLYSTYRENE PELLETS,
A RAW PLASTIC MATERIAL,

IS FED INTO THE MACHINE
THROUGH A NETWORK OF TUBES.

PLASTICS, AS WE KNOW
AND EXPERIENCE THEM TODAY,

ARE PRIMARILY DERIVED FROM
NATURALLY OCCURRING MATERIALS

SUCH AS OIL AND PLANT STARCHES.

BUT ACTUALLY, EARLY PLASTICS
WERE DERIVED FROM CELLULOSE,

DIRECTLY TAKEN
FROM PLANT FIBERS.

Narrator: ONCE THE PELLETS ARE
INJECTED INTO THE MACHINE,

THEY'RE MELTED AND PRESSURIZED.

PLASTIC IS INJECTED
INTO THE MOLD VERY QUICKLY.

THE BUILDUP OF PRESSURE PACKS
AND HOLDS THE MATERIAL TOGETHER.

INJECTION MOLDING MAY SEEM
LIKE A 21st CENTURY

MANUFACTURING TECHNIQUE,

BUT THE PROCESS HAS
A LONG HISTORY.

A VERY SIMPLE VERSION
OF INJECTION MOLDING

WAS ATTEMPTED
AS FAR BACK AS 1872

TO PRODUCE BILLIARD BALLS.

BUT IT REALLY TOOK OFF
AFTER WORLD WAR II

WHEN THERE WAS A HUGE DEMAND FOR
CHEAP, MASS-PRODUCED PRODUCTS.

INVENTOR JAMES HENDRY
DESIGNED A MACHINE

THAT USED A TURNING HEATED SCREW

BOTH TO MELT THE PLASTIC
AND TO INJECT THE MOLD.

IT REALLY WAS GROUNDBREAKING
BECAUSE TODAY THIS DESIGN

MAKES UP 95% OF ALL
INJECTION MOLDING MACHINES.

♪♪

Narrator: THE MOLTEN PLASTIC
BEGINS TO COOL

AS SOON AS IT MAKES CONTACT

WITH THE INTERIOR OF THE MOLD.

AS THE PLASTIC COOLS,

IT SOLIDIFIES INTO SHAPE.

TO GUARANTEE EFFICIENCY,

BANDAI UTILIZES THEIR SIGNATURE
COOLING PROCESS.

IN ORDER TO SPEED UP
THE MANUFACTURING PROCESS,

THE MOLDS ARE CHILLED SO
THAT WHEN THE HOT PLASTIC

HITS THE SURFACE OF THE MOLD,

IT COOLS DOWN MORE QUICKLY
AND THE OBJECT SETS FASTER.

Narrator: THIS PROCESS INCREASES
COOLING PRODUCTIVITY BY 20%.

DOWN THE ASSEMBLY LINE,

INJECTION MOLDING MACHINES
OPERATE AROUND THE CLOCK.

NEXT, AUTOMATIC GUIDED VEHICLES
TRANSPORT THE BOXES

TO A WAREHOUSE
WHERE THEY'RE STORED

UNTIL THEY'RE READY
TO BE DISPATCHED.

THE MODELS ARE SHIPPED
TO STORES AROUND THE WORLD,

BUT NOWHERE ARE THEY MORE
POPULAR THAN HERE IN JAPAN.

IN ITS TOKYO SHOP,
BANDAI GIVES GUNDAM ENTHUSIASTS

A HANDS-ON EXPERIENCE

ASSEMBLING SOME OF THEIR
FAVORITE ANIME CHARACTERS.

IN THE PROFITABLE BUSINESS
OF MODEL MAKING,

THESE TOY ROBOTS ARE SURE
TO DOMINATE THE MARKET

FOR LIGHT YEARS TO COME.

AND IT'S ALL THANKS
TO THE INDUSTRIAL INFRASTRUCTURE

AND PRECISION
CRAFTSMANSHIP

FOUND IN THE BANDAI
SUPER FACTORY.

COMING UP,
A EUROPEAN MANUFACTURER

IS FLUSHING OUT THE COMPETITION

BY PUSHING THE BOUNDARIES
OF DESIGN AND ENGINEERING.

♪♪

Narrator: LOCATED IN
STAFFORDSHIRE, ENGLAND,

IS THE ARMITAGE SHANK'S
BATH APPLIANCE

AND MANUFACTURING FACILITY.

SINCE 1851, THIS FACTORY
HAS BEEN PRODUCING

A WIDE VARIETY OF SANITARY
WARE APPLIANCES,

INCLUDING THEIR MOST RENOWNED
PRODUCT... TOILETS.

AND WHAT MAKES
THESE TOILETS UNIQUE?

THE MATERIALS THEY'RE MADE WITH.

THE PROCESS STARTS
WITH A DELIVERY

OF MORE THAN 165,000 POUNDS
OF IMPORTED CLAY.

♪♪

SO, YEAH, SO THIS
IS A CHINA CLAY

THAT'S COME IN THIS MORNING.

THIS IS MINED IN CORNWALL.

SO WE'VE GOT TWO TYPES OF CLAY
HERE, CHINA CLAY AND BALL CLAY.

THE BALL CLAY GIVES US
THE STRENGTH AND VISCOSITY.

AND THEN WE'VE GOT
THE CHINA CLAY.

IT'S A BIT MORE CRUMBLY BECAUSE
OF THE SET CASTING TIMES.

KAOLIN OR CHINA CLAY, AS IT'S
MORE COMMONLY KNOWN,

IS A RARE FORM
OF DECOMPOSED GRANITE

THAT HAS A SUPERFINE
POWDERY TEXTURE.

ONCE YOU MIX IT
WITH BALL CLAY

TO ADD STRENGTH AND PLASTICITY,

IT'S THEN READY TO BE WORKED
AND SHAPED

AND CAN BE MOLDED INTO FINE
CHINA OR TABLEWARE

OR EVEN TOILETS.

Narrator: TURNING CLAY INTO
PORCELAIN STARTS IN THE MIXING BAY.

TWO DIFFERENT TYPES OF CLAY,
SAND, AND A FEW CHEMICALS

ARE MIXED TOGETHER WITH WATER.

IT'S ALL MIXED TOGETHER
IN THESE 6,000 LITER TANKS

WITH ALL THESE BLUNGERS.

IT'S BASICALLY
A GIANT CAKE MIXER

MIXING ALL THE INGREDIENTS
TOGETHER TO MAKE LIQUID CLAY,

WHICH IS KNOWN AS SLIP
IN THE INDUSTRY.

Narrator: IN EACH MIXING
VAT OR BLUNGER, WATER AND CLAY

ARE MIXED TOGETHER
FOR 70 MINUTES.

ONCE MIXING IS COMPLETE,

THE LIQUID CLAY IS DISPENSED
THROUGH A GIANT FILTER OR SIEVE.

THIS PROCESS REMOVES
ANY IMPURITIES.

THE MACHINES IS BASICALLY
A VIBRATING TANK,

IT'S FITTED WITH ONE
OF THESE MEMBRANES.

AND IT SIFTS THROUGH THERE.

YEAH, I MEAN, THIS
IS THE KIND OF STUFF

WE MIGHT GET OUT OF THERE.

SOME COARSE MATERIAL,
SOME STONES.

WE DON'T WANT THAT
IN THE FINAL PRODUCT.

Narrator: ONCE THE UNWANTED
MATERIAL IS SEPARATED,

THE CLAY IS TURNED INTO
A SMOOTH PASTE.

IT LOOKS LIKE CHOCOLATE,
BUT I WOULDN'T TASTE IT.

Narrator: NEXT, THE LIQUID CLAY
IS PUMPED AND DISTRIBUTED

INTO A 265-GALLON HOLDING TANK,

WHERE IT'S MIXED
AT A CONSTANT TEMPERATURE.

SO IT'S BEEN MIXED
QUITE AGGRESSIVELY.

A LOT OF ENERGY
HAS GONE INTO IT.

WE NOW NEED IT TO CALM DOWN,
JUST SETTLE DOWN.

IT'S BASICALLY
AN AGING PROCESS.

Narrator: TRADITIONAL TOILETS
DATE BACK TO 1596,

WHEN SIR JOHN HARRINGTON,
AN ENGLISH COURTIER

AND THE GODSON OF
QUEEN ELIZABETH I,

DESIGNED THE FIRST
FLUSHABLE TOILET.

HIS DEVICE USED A 24-INCH
DEEP OVAL BOWL

FED BY WATER
FROM A RESERVOIR.

FLUSHING HARRINGTON'S TOILET

REQUIRED NEARLY EIGHT GALLONS
OF WATER,

WHILE TODAY'S TOILETS
USE LESS THAN ONE GALLON.

THE PROBLEM WITH THE DESIGN
IS THAT THE BOWL WASHED

STRAIGHT INTO A CESSPOOL BELOW,

SO THE STENCH OUTWEIGHED
THE CONTRAPTION'S CONVENIENCE.

HARRINGTON PROVED
THAT A TOILET WITHOUT A SEWER

IS JUST A GIGANTIC CHAMBER POT.

HIS NOVEL IDEA
WENT DOWN THE DRAIN.

[ FLUSHING ]

Narrator:
AND IN THIS FACTORY,

ARMITAGE SHANKS HAS IMPLEMENTED
ANOTHER INNOVATIVE CONCEPT

THAT DRASTICALLY CUTS DOWN
ON PRODUCTION TIME.

♪♪

Narrator: FOR MORE THAN
200 YEARS, ARMITAGE SHANKS

HAS BEEN PUSHING THE BOUNDARIES
OF DESIGN AND INNOVATION

TO MANUFACTURE CERAMIC
SANITARY WARE PRODUCTS.

TODAY AT THIS PRODUCTION
FACILITY,

THE USE OF MODERN MATERIALS

IS COMBINED WITH
THE LATEST TECHNOLOGY

TO PRODUCE MORE
THAN 1,500 TOILETS A DAY.

BACK ON THE PRODUCTION LINE,
THE LIQUID CLAY IS READY TO BE

TRANSFORMED INTO
THE FAMILIAR TOILET SHAPE.

TRADITIONALLY,
THE CASTING PROCESS

REQUIRED THE MATERIAL
TO BE POURED BY HAND,

BUT THANKS TO MODERN TECHNOLOGY,

AN INJECTION MOLDING MACHINE
PERFORMS THE TASK.

PREVIOUSLY IT WAS PLASTER MOLDS.

SO WE HAD A BIG ROW
OF PLASTER MOLDS

THAT PERHAPS LASTED
TWO TO THREE WEEKS

THAT HAD TO BE REPLACED.

WE HAD TO HAVE A
MOLD-MAKING DEPARTMENT

CONTINUOUSLY MAKING
PLASTER MOLDS.

THE THING WITH THE OLD WAY.

IT WAS THE WASTE AND THE MAN
HOURS AND MATERIALS

THAT USED TO HAVE TO GO
INTO THE PLASTER MOLDS.

THESE REUSABLE MOLDS
THAT ARE POROUS RESIN,

WE GET 20,000 TO 30,000
CYCLES OUT OF EACH ONE.

THE USE OF MODERN MATERIALS HAS
TRANSFORMED THE PRODUCTION LINE,

IT ENABLES IT TO WORK
CONTINUOUSLY 24 HOURS A DAY.

THERE'S NO STOPPING TO REPAIR
BROKEN CASTS OR MOLDS.

Narrator: WHEN THE TOILET FIRST
COMES OUT OF THE MOLD,

IT'S SOFT AND ALMOST JELLYLIKE.

A TECHNICIAN USES SPONGES
AND KNIVES TO SMOOTH DOWN SEAMS,

SHAPE THE RIM, AND CHECK
FOR ANY IMPERFECTIONS.

THIS WORK IS SO PRECISE
IT MUST BE DONE BY HAND.

ANY TOILET NOT UP
TO SNUFF IS RECYCLED.

ONCE THE TOILETS
ARE SHAPED TO PERFECTION,

THEY'RE TRANSPORTED
DOWN THE ASSEMBLY LINE

TO THE DRYING TUNNEL.

THE TOILETS GO INTO
THE 195 DEGREE DRYERS

FOR EIGHT TO 10 HOURS.

TO DRY THIS WARE OUT NATURALLY,

YOU'RE LOOKING AT
TWO TO THREE DAYS.

SO THIS TUNNEL DRYER IS AN
ESSENTIAL PART OF THE PROCESS.

Narrator: SINCE THE DRYING
PROCESS REMOVES MOISTURE,

THE SIZE OF THE TOILET
SHRINKS BY 2.5%.

NEXT, EACH TOILET IS INSPECTED
FOR ANY REMAINING IMPERFECTIONS,

THEN A TECHNICIAN
BLENDS IN THE SEAMS,

REMOVES ANY ROUGH EDGES,

AND MAKES ONE FINAL
VISUAL INSPECTION.

NOW THE TOILETS ARE READY
FOR GLAZING.

ONCE THE GLAZE IS ON THE PIECE,
THERE'S NO GOING BACK.

IT NEEDS TO BE PRISTINE.
IT NEEDS TO BE PERFECT.

Narrator: A ROBOTIC ARM SPRAYS
FOUR LAYERS OF LIQUID GLAZE

CONTAINING ALUMINUM OXIDE
AND SILICA SAND.

IT MAY SOUND OBVIOUS, BUT A
TOILET NEEDS TO BE WATERPROOF.

AND IF YOU JUST HAD PORCELAIN
AND FIRED IT,

YOU'D HAVE A SURFACE
WHICH WAS SLIGHTLY POROUS.

SO YOU NEED TO GLAZE
THAT PORCELAIN.

AND ONCE GLAZED,
THE LOO ACTUALLY BECOMES

THE CLEAN, HYGIENIC OBJECT
WE ALL KNOW AND LOVE.

Narrator:
AS A LEADER IN THE INDUSTRY,

ARMITAGE SHANKS HAS COME
A LONG WAY

SINCE THE COMPANY
WAS FIRST FOUNDED

MORE THAN 200 YEARS AGO.

IN THE LATE 1960s,

THE COMPANY CREATED
AN AVOCADO BATH LINE,

WHICH BECAME VERY POPULAR
IN COMMERCIAL

AND RESIDENTIAL HOUSEHOLDS
AROUND THE WORLD.

HOWEVER,
THE RETRO BATHROOM SUITE

DIDN'T STAND THE TEST OF TIME

AND FIZZLED OUT OF PRODUCTION
BY THE LATE 1980s.

WE CAN DO ANY COLOR YOU WANT,
AS LONG AS IT'S WHITE.

Narrator: FOUNDED IN 1817,

THE COMPANY EMERGED
DURING A TIME

WHEN THE LACK OF SANITATION
WAS SO BAD IN THE U.K.

THAT LIFE EXPECTANCY
WAS ONLY 40 YEARS.

FLUSHING TECHNOLOGY WAS IMPROVED
THROUGH THE EFFORTS

OF ALEXANDER CUMMINGS,

WHO INVENTED THE S-BEND PIPE,
AND LATER, THOMAS CRAPPER,

WHO IMPROVED UPON CUMMINGS
DESIGN, INVENTING THE U-BEND.

THE DIRECT PIPE THAT CONNECTED
THE TOILET WITH A SEWER

WOULD FLUSH THE WASTE AWAY,

BUT UNFORTUNATELY IT WOULD ALSO
LET SEWER ODORS

PERCOLATE BACK UP,

SO AN AIRTIGHT SEAL
HAD TO BE CREATED.

HE MADE A U-BEND IN THE PIPE.

WATER SETTLES AT THE BOTTOM
OF THE "U,"

MAKING A SEAL AND STOPPING
THE SMELLS FROM COMING BACK UP.

WHEN THE TOILET IS FLUSHED
AGAIN,

THE WATER IS REPLENISHED
AND THE SEAL REMADE.

Narrator: THANKS TO THE
INGENUITY OF THEIR ENGINEERS,

ARMITAGE SHANKS WAS THE FIRST
BUSINESS TO CONNECT TOILETS

TO SEWER SYSTEMS,

RAPIDLY IMPROVING
PUBLIC SANITATION.

BACK ON THE ASSEMBLY LINE,

THE GLAZED TOILETS
ARE READY FOR FIRING.

FIRING IS THE PROCESS
OF TURNING CLAY AND GLAZE

INTO LONG-LASTING WATERPROOF
PORCELAIN USING EXTREME HEAT.

THE TOILETS ARE PLACED
ON A FIREPROOF PALLET

AND HEATED AT 2,192 DEGREES.

Spink: THE FIRING PROCESS ITSELF
CAUSES A CHEMICAL REACTION.

THIS CHEMICAL REACTION FUSES THE
BODY OF THE CLAY TO THE GLAZE.

Narrator:
AFTER 16 HOURS IN THE KILN,

THE PORCELAIN IS FINALLY
SOLIDIFIED.

THE TOILETS ARE COOLED
FOR EIGHT HOURS.

THEN THEY'RE CHECKED FOR CRACKS.

AND NOW 50 HOURS LATER,
HERE WE HAVE IT,

A BEAUTIFUL TOILET READY
FOR A LIFETIME OF SERVICE.

IT'S ONE OF THOSE BRAND NAMES

THAT JUST GETS INSIDE
OF YOUR HEAD.

WHY? BECAUSE YOU HAVE TIME
TO CONTEMPLATE IT ALONE.

ARMITAGE SHANKS HAS BEEN
A CHARACTER IN A MOVIE

AND IN A VIDEO GAME,

PLUS THE INSPIRATION
FOR SIX POP SONGS,

AND THE TITLE
OF A BRITISH PUNK-ROCK BAND.

Narrator: OVER TIME,
ARMITAGE SHANKS HAS RISEN

TO THE TOP OF THE INDUSTRY.

TODAY, THE COMPANY CONTINUES
TO REVOLUTIONIZE THE BRAND

THROUGH THEIR USE
OF MODERN MATERIALS

AND BY IMPLEMENTING THE LATEST
MANUFACTURING OPERATIONS

AND TECHNOLOGIES
ON THEIR ASSEMBLY LINES.

ALL THESE ELEMENTS COMBINED

MAKE THIS FACTORY
A SUPER FACTORY.

[ FLUSHING ]