Ultimate Factories Season 3, Episode 5: Caterpillar

Rolls-Royce

The Phantom is the first Rolls-Royce motorcar to be introduced since the company was acquired by BMW in 1998. Each Phantom is a unique combination of state-of-the-art technology and old-world craftsmanship, constructed with meticulous attention to detail. Manufacture of the Phantom begins in Unterhallerau, Germany, where its strong, stiff and lightweight space frame chassis is built. Each space frame and body shell assembly is then sent to BMWs factory in Dingolfing, Germany for corrosion-resistance treatment and primer paint. Next, each Phantom is shipped to a manufacturing facility constructed by BMW specifically to build the new generation of Rolls-Royce motorcars. It takes an average of 450 hours and the skills of hundreds of dedicated craftspeople, artisans, designers, engineers, mechanics, painters, sewing machinists and others to hand-build each car. At a base price of $380,000, the Phantom comes equipped with an impressive list of standard amenities including 90 square yards (75 sq meters) of A-grade Bavarian leather upholstery and book matched interior wood trim, hand-crafted from exotic veneers, all of which are fashioned right in the main assembly building of the Goodwood plant. With the Rolls-Royce customization, or bespoke program, however, the options are limited only by the boundaries of the buyers bankroll and imagination.

Camaro

What does it take to build a classic car with 21st century technology? Now, after nearly a decade off the factory line, Chevy is reintroducing the 2010 Camaro SS. NGC visits the 10-million-square-foot factory, one of the largest auto plants in the world, where the car is stamped from cold raw steel and assembled by high-tech precise robots and nearly 5,800 employees, to create the car's specially designed "unibody" construction.

45 min

Porsche

Get inside the famous House of Porsche and see how they create the Porsche 911, one of the most influential and recognizable vehicles in the world. Every distinctive element is manufactured at the Zuffenhausen factory in Stuttgart, Germany, a historical industrial monument. We'll examine the Porsche factory's innovative system of lifts, elevators and bridges, which conveys car bodies 50 feet above a public highway.

45 min

Ikea

In 36 countries, in 296 stores IKEA represents a distinct design and an affordable price. Each year nearly 600 million customers choose IKEA. From teaspoons to living rooms, the entire contents of a home are designed, manufactured and supplied in a huge variety of styles, colors and models... almost 10,000 items. To get the job done, suppliers in 54 countries carry out IKEAs vision. In Zbaszynek, Poland, IKEAs largest wood production plant in the world, creates 2 million tables, chairs, sofas and recliners each year. Nearby, in Nowe Skalmmierzyce, IKEAs the companys textile supplier builds over 500 pieces of upholstered furniture daily. In southern Sweden, three ultimate factories create IKEA staples. In Almhult, the prototype for every product is born and an advanced mass produced carpentry factory creates state of the art kitchens. In Kattilstorp, the classic Billy Bookcase is manufactured. And in Hultsfred, the foundation of most IKEA furnishings, the strong, hardwearing particle board is born.

NYC Subway Car

Join us as we follow the creation of the car that moves 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 mass transit system over 100 years old. These innovations include LCD screen maps, a passenger emergency intercom system, soundproofing and a braking system that actually generates electricity and returns power to the third rail. It starts as sheets of metal in Sao Paulo, Brazil where human skill, fire, and steel come together to build the body shell. After a month-long voyage, the body arrives in Hornell, NY for final assembly, motor installation, and testing. Once assembled the R-160 weighs nearly 85,000 lbs and contains 24 miles of wiring. This car is built to last 40 years, to withstand the force of 1.6 billion riders per year, and survive in one of the worlds toughest environments New York City.

45 min

Episode 7