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From the tropical production site of an iconic liquor, to the heart of European engineering finesse, the series returns with an exciting exploration of how some of the world's most famous products are made.

EA Sports: FIFA 2012 -

This video game is taking the beautiful game to a whole new level. The game creators are treated like rock stars, for very good reason. This video game is so close to reality that even pro-footballers use it to test their skills against the opposition. Enter the EA factory in Burnaby Canada and find out how these brilliant minds took the game of football off the field and turned it into a virtual masterpiece.

Supercars -

First, travel to the little village of Sant’Agata Bologna, Italy, where the “bad boys” of the sports car pantheon are hand-building the fastest Lamborghini ever – the Murcielago SV. Then head north for the royal treatment at the Rolls-Royce factory in England and see why each ultra-luxurious Phantom takes two months to build. Watch how IKEA’s Billy bookcase – 40 million of which have been sold over three decades – comes to be in a matter of minutes at an IKEA factory in Sweden. Shift gears at the Audi factory in Germany and see why the revolutionary R8 road car is forcing Hollywood to change its endings before racing to visit the birthplace of the iconic Porsche 911. Finally, fly south to Brazil where each New York Super Subway car gets over 2,500 welds before it journeys north to New York for assembly and final inspection.

EPISODE GUIDE

  • Megafactories: Audi
    Go inside the famed carmaker’s factory in Germany to see Audi break its elegant sedan image to craft a revolutionary sports car. Audi’s R8 is a mid-engine, two-seater with explosive power and a super-smooth ride. With an ultra-light aluminium space-frame, high-tech fuel injection and a v-10 engine, the R8 can rocket from 0 to 96 kilometres per hour in just 3.8 seconds. Meticulously hand-built and requiring about a week to construct, the R8 is manufactured in the true sense of the word; manually - only 6 robots work on the R8. It will require over 5,000 different parts – fitted mostly by hand – for maximum precision and a great deal of endurance. Just 120 of Audi’s most experienced workers qualify to work on the R8 assembly line. In one day, Audi will build 1,100 cars but only 20 R8’s. Featured in numerous films including Iron Man and Transformers, there is no question that the R8 is definitely turning heads.
  • Megafactories: Lamborghini
    Lamborghini comes with two problems: “the speed limit and the police”. The “bad boy” of sports cars, is gearing up to deliver the fastest Lamborghini ever made – the Murcielago SV. Going from 0 to 99kph in just 3.2 seconds, it can achieve a top speed of 340kph. With only 350 in production, the Murcielago SVs is Ultra-Exclusive. Lamborghini painstakingly assembles these cars almost entirely by hand – everything from the engine, body, paint and upholstery, completing just 2.7 cars per day. The Lamborghini Murcielago SV gets its power from a hand-built v-12 engine that delivers a phenomenal 670 horsepower and takes 12 hours to build. The factory “hot tests” every engine by running it in a special diagnostics room to analyse its mechanical performance as well as its quality, before undergoing a 40-minute road test at speeds of over 136 kilometres per hour on Italian country streets surrounding the factory.
  • Megafactories: IKEA
    From teaspoons to living rooms, IKEA’s 10,000 item product line attracts nearly 600 million customers annually. It all starts at IKEA headquarters in Sweden where designers and master craftsmen create close to 2,000 prototypes each year while technicians carry out 50,000 experiments on new and existing products. At IKEA’s particleboard mill, sawdust, wood chips and timber feed into one end of a highly-automated factory line and ready-made boards come out the other. The particleboard immediately ships out to a dozen suppliers in Scandinavia to become an IKEA classic: the Billy bookcase. IKEA has sold over 40 million Billy bookcases in three decades. Every week, their state-of-the-art automated manufacturing process builds 130,000 bookshelves as 20 robots fold, lift and place bookcase parts into a complete kit. Virtually every six seconds, robots at ten major stations repeat the motion in heavy rotation – producing 20 bookcase packs per minute – that’s a production rate of almost 10,000 units daily.
  • Megafactories: Super Subway
    Witness the creation of a car that will move millions. The R-160 Subway car is the newest member of the New York City Transit fleet – bringing 21st century safety and technological innovations to a 100-year old mass transit system. Each car starts as sheets of metal in Brazil where workers spend nearly 60 days crafting the body shell. It is a 23-step process done almost entirely by hand and requires over 5,000 welds. The subway shells are tested to make sure they are water-tight, shrink-wrapped and shipped on a month-long journey to New York. Teams then install the interior floor, electrical wiring, window and door panels, as well as the car’s four traction motors, wheels, breaks, carbon-steel seats and more. It is an arduous process considering that one car has over 11,000 parts. It takes nearly two months, over a 1,000 workers and an exhaustive inspection process to get the R-160 fit for service.
  • Megafactories: Rolls-Royce
    Since its Silver Ghost was branded the “best car in the world in 1907”, Rolls-Royce has developed its next generation of ultra-luxury automobiles: The Phantom. Each Phantom begins in Germany, as a collection of over 500 aluminium and alloy parts hand-welded together to build an incredibly strong, stiff and lightweight space-frame chassis before being shipped to another German factory for a high-tech corrosion-resistance treatment and a primer paint application. Next, each Phantom is delivered to a cutting-edge, environmentally-friendly Rolls-Royce factory in England where technicians use a motorised sled to lift and install everything from the engine to the axles. At a base price of U.S. $380,000, the Phantom features eight square metres of top-grade Bavarian leather upholstery, a high-tech soundproofing that keeps virtually all road noise out, and a 15-speaker, nine-channel sound system. The Phantom is also highly customisable; options are limited only by the buyer’s imagination and bankroll.
  • Megafactories: Porsche
    One of the world’s most iconic sports cars, the Porsche 911 is available in 14 variations – including the Targa, which features a complete glass roof and the GT2: a street-legal race car capable of 312 kilometres per hour. However, the basic DNA of the Porsche 911 remains the same: rear engine, rear wheel drive and a classic, contoured look. The Porsche 911 factory features multiple, three-story buildings and a 117 station assembly line. Workers at each station have just over 5 minutes to complete their tasks before the next car moves into place – each 911 takes just 15 hours to build. To manage this feat, the factory deploys a small army of robots to move car parts, doors and engines for delivery to the assembly line just at the moment they are needed. Each of the 100,000 cars produced at the Porsche Factory is assembled to individual customer specifications and, because each car is still made to order, the possibilities are endless.
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