Mega Manufacturing: Series 1
The series offers behind the scenes of the biggest and most advanced factories in the world, focusing on the creation of inimitable unique products. From gigantic factories the size of cities to the largest passenger airplanes in the world everything about their creation is special. And because of their mega size, they come with their own challenges and drama.
Part 1: Giant Aircraft Manufacturing an Airbus A350
It takes 1800 highly-skilled specialists in Toulouse, France, and 2.5 million individual parts, delivered from all over the world, to assemble this masterpiece of aeronautic engineering. The individual parts of the aircraft travel from various Airbus plants in Europe to Toulouse: the front and centre sections from Saint-Nazaire in France, the tail section from Hamburg, the wings from Broughton in Wales and Bremen, and the tail fin from Getafe in Spain. The factory in Toulouse is supplied with these parts by a specially developed transport aircraft, the Beluga.
Part 2: Sany Excavator Factory
Lingang, China. Home to one of the largest and most modern excavator factory in the world! 1000 square meters of production area, equipped with high-tech machines of the latest generation. By this means China’s market leader Sany wants to become the number one in the world!
Part 3: Pirelli Tyre Manufacturer
It is the most renowned tyre manufacturer in the world: Pirelli. Their capacity: 75 million car tyres a year. 32,000 employees worldwide, including 1,400 engineers. The most prestigious car manufacturers in the world rely on their experience. We follow the production of the P-Zero, Pirelli’s flagship product. It takes: 100 constituent materials,
Part 4: Custom Made Volvo Trucks
Trucks: Kings of the road with enormous power. Their manufacture demands a good eye, absolute precision and above all: perfect logistics. One of the world’s largest truck factories is located in Belgium, close to the romantic town of Ghent. It’s the ideal location, close to thousands of customers across Western Europe. This is where Volvo produces its bestseller: the all-time all-rounder “FH” – one of the most popular trucks in Europe with the most powerful engines in the industry!
Part 5: Porsche Macan Car Manufacturer
The Porsche Macan: Mass car production with a level of customization that comes close to manufacturing. Each individual Macan car body is checked with utmost precision. The same applies to the paint surface and the assembled car. The extent of the individual quality control is unique in mass production – and for Porsche, an absolute necessity.
Part 6: Largest Fire Truck Manufacturer
What is created here is intended to save lives for once: It is the largest manufacturer of fire trucks in the world: Pierce Manufacturing in Wisconsin, USA. 1400 trucks are being built here every year – and each truck is one of a kind. Customers determine every detail from the first sketch on the 3D model to the finished truck. More than 13,000 individual components – most of them laboriously crafted by hand – are turned into an absolutely individual fire-fighting vehicle. Even the lettering and coats of arms so popular in North America are the result of Pierce’s manual work with brushes and genuine gold leaf.