{"id":36954,"date":"2018-09-07T06:00:02","date_gmt":"2018-09-06T21:00:02","guid":{"rendered":"https:\/\/www.panamera-life.com\/?p=36954"},"modified":"2019-09-21T14:38:04","modified_gmt":"2019-09-21T05:38:04","slug":"new-cayenne-factory","status":"publish","type":"post","link":"https:\/\/www.panamera-life.com\/en\/entry\/new-cayenne-factory\/","title":{"rendered":"Porsche New Cayenne: An In-Depth Look at the Factory Production Process! (A Summary of the TV Program)"},"content":{"rendered":"

Porsche Cayenne Feature<\/h3>\n

In our household, any TV program with the keyword “Porsche” in the title is automatically recorded (what kind of household is this? lol)<\/span>. So naturally, the program Discovery Channel<\/a> recently aired, titled “High-End SUVs of the World: Porsche Cayenne”<\/strong>, was recorded as well.<\/p>\n

It was an episode focusing on the production process of the new Cayenne at the factory and the history of the Cayenne. My husband found it quite interesting, so despite saying, “I’m not really interested in factory production processes,” I watched it casually\u2014and surprisingly, I found it full of things I didn\u2019t know and very fascinating.<\/p>\n

The Cayenne That Saved Porsche from Bankruptcy<\/h3>\n

Porsche launched its first model bearing the Porsche name, the Porsche 356<\/strong>, 70 years ago in 1948. Since then, it evolved as a two-seater sports car manufacturer, but around 1993, Porsche faced financial difficulties and was on the brink of bankruptcy<\/strong>.<\/p>\n

Annual sales were only about 10,000 to 12,000 units (compared to 246,000 units sold worldwide in 2017)<\/span>. So Porsche made a bold strategic shift. They launched their first-ever SUV, a vehicle completely opposite to sports cars<\/strong>.<\/p>\n

However, longtime Porsche fans at the time fiercely opposed the Cayenne\u2019s debut, saying things like “Are they trying to kill the brand?” “Why on earth is Porsche making a 4-door SUV?”<\/strong>. The front end design, which resembled the 911, was also initially met with many negative opinions.<\/p>\n

But when the Cayenne hit the market, it became Porsche\u2019s biggest hit ever. It was well-handling, retained Porsche\u2019s sporty character, was powerful, and excelled off-road\u2014truly a versatile vehicle.<\/strong> The first-generation Turbo model featured an unusual-for-an-SUV 400-horsepower V8 twin-turbo engine, making it a car that combined both “fun” and “practicality,” and it sold like hotcakes.<\/p>\n

The Cayenne not only saved Porsche from a crisis but also marked the beginning of Porsche\u2019s transformation from a “sports car maker” to a sports car manufacturer that builds sportier cars than competitors in every segment.<\/strong><\/p>\n

Wow, the Cayenne is seriously amazing! (\uff1b\uff9f\u0414\uff9f)<\/span><\/p>\n

We could even say that the current Panamera exists thanks to the success of the Cayenne.<\/p>\n

About the New Cayenne Production Factory<\/h3>\n

Do you know where the new Cayenne is manufactured? I had assumed it was made at Porsche\u2019s Leipzig factory in Germany (the Panamera is made at the Leipzig factory)<\/span>, but it is actually produced at Volkswagen\u2019s assembly plant in Bratislava, the capital of Slovakia in Central Europe.<\/strong>
\n*Photos borrowed from the Discovery Channel program “High-End SUVs of the World: Porsche Cayenne”<\/strong><\/span><\/p>\n

\"\"<\/p>\n

\"\"<\/p>\n

I had no idea.<\/p>\n

This factory is equipped with the latest technology, and 600 employees work in three shifts around the clock<\/strong> to produce the new Cayenne. The daily production volume is 400 units.<\/strong> I thought, “Wow, 400 units a day!?” but apparently, the Cayenne accounts for over 30% of Porsche\u2019s global sales.<\/strong><\/p>\n

\"\"<\/p>\n

This factory was built in the early 1970s. The ownership changed, and in the early 1990s, the factory became part of Volkswagen.<\/strong> Initially, handmade Volkswagen Passats were produced here, but over time, the range of models expanded, equipment was upgraded, and it evolved into Volkswagen\u2019s most advanced factory.<\/strong><\/p>\n

\"\"<\/p>\n

The site covers an astonishing 2 million square meters. Since the Tokyo Dome is about 46,000 square meters, that\u2019s roughly 43 Tokyo Domes!?<\/p>\n

\"\"<\/p>\n

\"\"<\/p>\n

That\u2019s huge! (\uff1b\uff9f\u0414\uff9f)!!<\/span><\/p>\n\n\n\n
\u2192Next page: Finally, a sneak peek inside the new Cayenne production process!<\/strong><\/a><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

<\/p>\n

New Cayenne Production Process \u2460<\/h3>\n

The factory process is divided into four sections: \u201cPress Line,\u201d \u201cBody Manufacturing Line,\u201d \u201cPainting Line,\u201d and \u201cAssembly Line.\u201d<\/strong><\/p>\n

First, on the press line, 750 robots produce 400 body shells per day.<\/strong> Almost all of this process is done by robots, and it takes about 11 hours to make one body shell.<\/p>\n

\"\"<\/p>\n

Next, the body manufacturing line takes over. The work passes from robots to human hands. Production is carried out under strict standards, from panel gaps to bolt tightness.<\/strong><\/p>\n

\"\"<\/p>\n

Here, all work is done manually, but to maintain high quality, heavy parts are handled with machine assistance, while assembly is basically completed by hand.<\/strong> After all these steps, the car moves to the painting line.<\/p>\n

On the painting line, 88 robots paint one Cayenne over 18 hours.<\/strong><\/p>\n

\"\"<\/p>\n

\u202618 hours to paint one car!? (\uff1b\uff9f\u0414\uff9f)<\/span><\/p>\n

First, a base coat as thin as a human hair is applied, followed by a clear coat. After this careful priming, the refined painting robots apply the color.<\/p>\n

\"\"<\/p>\n

The robot\u2019s head spins at about 50,000 rotations per minute.<\/p>\n

\"\"<\/p>\n

I don\u2019t really understand it, but 50,000 rpm sounds impressive (lol).<\/p>\n

New Cayenne Production Process \u2461<\/h3>\n

After painting, the car moves to the assembly line. Here, the engine, seats, bumpers, and interior<\/strong> are installed. Porsche pays great attention to the working environment of its employees and continuously improves it to be among the best in the industry.<\/p>\n

Employees work standing on wooden boards designed ergonomically to make their tasks easier.<\/p>\n

\"\"<\/p>\n

The body is suspended at the worker\u2019s height for easy access, and equipment allows comfortable seated work inside the car.<\/p>\n

\"\"<\/p>\n

Heavy panoramic roofs and seats weighing over 30 kg are mostly transported by machines, with workers guiding them into place by hand.<\/p>\n

\"\"<\/p>\n

Porsche offers a wide range of options with countless combinations, and on this assembly line, parts are gathered according to customer orders and installed by hand.<\/p>\n

\"\"<\/strong><\/p>\n

With around 5,000 parts in total, inventory management is a huge challenge.<\/strong><\/p>\n

Afterwards, the front and rear bumpers, front and rear wheels, and hood are installed, finishing with the emblem.<\/p>\n

\"\"<\/p>\n

If I could work at this factory, I\u2019d want to be in charge of the emblem installation (taking the best part at the end lol)<\/span>. The person responsible said, “I\u2019m very proud to be in charge of this task.”<\/strong> I envy them.<\/p>\n

New Cayenne Production Process \u2462<\/h3>\n

Meanwhile, on the sub-line, the powertrain (the system that transmits engine power to the drive wheels, including engine, clutch, transmission, driveshaft, etc.)<\/span> is installed. The heart of the car\u2014the engine\u2014is handmade one by one at Porsche\u2019s headquarters factory in Stuttgart, not Bratislava.<\/strong><\/p>\n

\"\"In 2015, Porsche invested over 80 million euros to build this factory. While there were just over 100 employees in the early 1950s, the engine manufacturing division now employs 1,200 people. It takes about 6 hours to build one engine, with 200 engines produced daily.<\/strong><\/p>\n

\"\"<\/p>\n

Completed engines are transported 800 km from Stuttgart to the Bratislava factory.<\/p>\n

Since powertrain types vary by grade and engine, pin colors are assigned by engine type<\/strong> to avoid mistakes and improve efficiency. For example, the V6 FSI uses “red,” so parts are installed on red pins to ensure correct assembly.<\/p>\n

\"\"<\/p>\n

New Cayenne Production Process \u2463<\/h3>\n

The completed powertrain moves to the next stage, the \u201cmarriage station,\u201d<\/strong> where the body and powertrain are joined. Usually, there is one marriage station, but this factory has six, ensuring high quality through careful, step-by-step assembly.<\/p>\n

Cables are connected, and the interior is finished,<\/p>\n

\"\"<\/p>\n

\"\"<\/p>\n

and after 7.5 hours, the Cayenne is finally drivable. Turning the ignition key to start the engine is the best moment for employees, when their long efforts take tangible form.<\/strong> The factory is filled with a sense of accomplishment.<\/p>\n

\"\"<\/p>\n

There is one more crucial step for the finished car: quality control checks.<\/strong> Inspectors thoroughly examine the vehicle to ensure there are no issues. Only after passing this check is a Cayenne complete.<\/p>\n

\"\"<\/p>\n

Ta-da! (lol)<\/p>\n

The Legacy of the New Cayenne<\/h3>\n

The Cayenne is a 4-door sports car capable of off-road driving. Its introduction drastically changed Porsche\u2019s customer base. It became a car not just for a wealthy few but an ultimate sports car in SUV form suitable for everyday use, broadening its appeal.<\/strong><\/p>\n

Due to its immense popularity, making bold model changes is difficult.<\/strong> Considering the risk of losing loyal fans and users, the third-generation new Cayenne has evolved further without drastically changing its appearance or core features.<\/strong><\/p>\n

Today\u2019s Porsche owes much of its success to the Cayenne. Following Porsche, luxury automakers have all developed, produced, and sold SUVs combining excellent driving performance and luxury.<\/strong> (Even Ferrari is rumored to be launching an SUV.)<\/span><\/p>\n

The Cayenne\u2019s debut not only saved Porsche but also significantly changed the automotive industry.<\/p>\n

That\u2019s the content aired on the program.<\/p>\n

I see now\u2014knowing the scale of equipment, processes, and people involved, and that you can buy this for around 10 million yen, it almost feels like a bargain (-_-).<\/strong> If someone handed me 10 million yen and said, “Go build a Cayenne,” I\u2019d never manage it in a lifetime.<\/p>\n

When I finished writing this article, I said, “Alright! Finally, I\u2019ve written the Cayenne article!” and my husband joked, “This isn\u2019t a blog post, it\u2019s basically a report article (lol).”<\/strong><\/p>\n

True\u2026 someday, I\u2019d love to visit a factory for an actual interview.<\/p>\n","protected":false},"excerpt":{"rendered":"Porsche Cayenne Feature In our household, any TV program with the keyword “Porsche” in the title is automatically recorded (what kind of household is this? lol). So naturally, the program Discovery Channel recently aired, titled “High-End SUVs of the World: Porsche Cayenne”, was recorded as well. It was an episode focusing on the production process of the new Cayenne at the factory and the history of the Cayenne. My husband found it quite interesting, so...","protected":false},"author":0,"featured_media":4760,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":"","_locale":"en_US","_original_post":"https:\/\/www.panamera-life.com\/?p=4697"},"categories":[43],"tags":[189],"yoast_head":"Porsche New Cayenne: An In-Depth Look at the Factory Production Process! 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