An enormous output and yet, every-truck custom-made: this is Volvo Trucks in Belgium.
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! Approximately two hundred trucks each day! Each one unique: every truck leaving this factory is different: Mega Manufacturing individually tailored to customer requirements in a feat of logistical perfection. Timed to the minute. Around one thousand five hundred individual parts are installed by the workers in two hundred and ten operations over eight hours from the simple unadorned chassis - to a state of the art truck.
This Mega Manufacturing takes huge amounts of energy. But surprisingly without CO2 emissions. Volvo Trucks in Belgium was the first carbon-neutral car factory in the world. As early as 2009.
Green energy, perfect logistics, a gigantic, fully automated warehouse, modern robots: the factory is still high-tech. But nothing works here without well-trained people. Volvo Trucks calls themself a „people factory“. At the moment they are testing how to support their highly-trained workforce with new high-tech equipment: exoskeletons and virtual reality glasses allow workers and computers to become one! It could become the truck factory of the future!
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! Approximately two hundred trucks each day! Each one unique: every truck leaving this factory is different: Mega Manufacturing individually tailored to customer requirements in a feat of logistical perfection. Timed to the minute. Around one thousand five hundred individual parts are installed by the workers in two hundred and ten operations over eight hours from the simple unadorned chassis - to a state of the art truck.
This Mega Manufacturing takes huge amounts of energy. But surprisingly without CO2 emissions. Volvo Trucks in Belgium was the first carbon-neutral car factory in the world. As early as 2009.
Green energy, perfect logistics, a gigantic, fully automated warehouse, modern robots: the factory is still high-tech. But nothing works here without well-trained people. Volvo Trucks calls themself a „people factory“. At the moment they are testing how to support their highly-trained workforce with new high-tech equipment: exoskeletons and virtual reality glasses allow workers and computers to become one! It could become the truck factory of the future!
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TVTranscript
00:00Trucks. Kings of the road with enormous power.
00:05Their manufacture demands a good eye, absolute precision, and above all, perfect logistics.
00:12The logistics part is very important. For a company like ours, it makes all the difference.
00:17It determines whether we win or lose.
00:21The most powerful engines in the industry. For approximately 200 trucks each day.
00:27Each one unique, built to the customer's specification, in a feat of logistical perfection.
00:36Time to the minute.
00:38The Volvo FH, one of the most popular trucks in Europe, and every single one must be absolutely reliable and safe.
00:57Situated just outside the Belgian town of Ghent, lies Volvo's largest truck manufacturing plant.
01:11It's the ideal location, close to thousands of customers across Western Europe.
01:17Approximately 42,000 trucks are produced here each year, including their bestseller, the Volvo FH.
01:28420 up to 750 horsepower, two up to four axles, gross combination weight of over 70 metric tons, price starting at 85,000 euros.
01:40The MEGA factory's day begins at the port of Ghent, at 6 a.m., with a daily container ship from Sweden.
01:53It delivers the most important parts for building the FH.
01:58Yannick Maas is responsible for unloading the shipment, and he's under considerable time pressure.
02:04The challenge is to unload the ship, and then load it again as quickly as possible.
02:11This has to be done in one shift, so that the ship can set sail again on time.
02:17The containers have to be off as quickly as possible, so that the parts are available at the factory on time.
02:25Things happen in rapid succession now, trailer for trailer.
02:34Around 75 of the containers on the ship, each weighing up to 30 metric tons, are destined for the MEGA factory.
02:47Secured with a special anchoring system, and parked as close as possible to maximize load capacity aboard ship,
02:54these need to be landed and on the road as soon as possible.
02:58They contain everything from steel girders for the chassis, axles, gearboxes, and small items,
03:07to radios, microwaves, and truck engines, all locked, loaded, and ready to continue their journey to the factory.
03:20Another key component of the Volvo FH has just arrived at the port too, this time by train.
03:28The cabs.
03:40They come from Sweden as well.
03:43The specialists in Ghent turned the raw, naked cab into a completely furnished, long-haul truck cab,
03:50customized according to the customer's wishes.
03:53These stickers indicate the cab model and chassis number.
04:00They are here on our list too.
04:02Unfortunately, they are not always loaded onto the train in the right order.
04:07For instance, 448 is here and beside it 440.
04:11So, we first have to line up the cabs properly on the parking lot here, so they arrive at the factory in the correct order.
04:21Everything in the factory is governed by the chassis numbers.
04:28They determine the order in which the trucks are built.
04:31Which is why the raw, naked cabs have to be in the right order here too.
04:37And because they are already painted, care must be taken to avoid scratching them.
04:43The forks of the forklift truck are fitted with special protective guards.
04:53This ensures they don't come into direct contact with the cabs and scratch them.
04:57The freight wagons are custom-built so that the cabs fit exactly and don't get damaged during transport.
05:07There are three different cab sizes available and 650 color options.
05:13The most popular color? White.
05:16Once properly ordered, they immediately head to the factory by truck.
05:21It's vital that the cabs arrive at the factory on time.
05:28Although we have a buffer of around 40 cabs, we have to maintain a continuous supply.
05:36Otherwise, production would grind to a halt and that would be a big problem.
05:43Agreed delivery dates could be missed, which would be disastrous for customer relations and their brand image.
05:50All the components that make up the Volvo FH are now on their way to the factory.
05:57The truck plant consists of four main sections.
06:02The fitting center, a huge tire and rim warehouse.
06:08The market adaption center, for the seemingly infinite customizations and special requests.
06:14The cab trim, the large cab assembly building, and the vast main assembly building, the heart of the factory.
06:24The truck is assembled here in the 75,000 square meter main assembly building.
06:30At the center of the building, the twin track assembly line, 420 meters long.
06:35Piece by piece, a thousand workers assemble one of the most popular trucks in the world.
06:51The Volvo FH.
06:53It consists of three main sections.
07:04The steel chassis forms the basis.
07:08In the middle, the heart of the brake system, the air compressor.
07:11The axles are fitted to the chassis.
07:17The number depends on the customer's requirements.
07:20Then comes the mighty engine.
07:22The last major section needed to complete the truck is the cab.
07:28Each one unique.
07:30Everything begins with the steel girders.
07:33Until recently in containers at the port, a side loader forklift now transports them into the main assembly building.
07:44A side support measures five and a half to twelve and a half meters in length, depending on the truck version.
07:51Two side supports form the subframe of the FH, the chassis.
07:56Two workers start by applying a simple white adhesive tape to the side supports.
08:01This will act as a guide.
08:09They then mount a cross support.
08:11It connects the long side supports.
08:16And now, the sticker tape comes into play.
08:20It's there so that the assembly line workers know exactly where they have to put which bolt.
08:25What kind of bolts they have to put.
08:29There are over fifty different bolts, screws and rivets.
08:34And the side support can have up to 330 holes.
08:38Lots of room for costly error.
08:40Production manager Kuhn Lehmans has an overview of the entire production operation.
08:51And he knows, a mistake made at the beginning could have fatal consequence.
08:55What the workers do here is very important.
09:00It's the start of production.
09:02All of the downstream assembly is based on this frame.
09:05Everything done afterwards depends on the workers here correctly installing every part.
09:10A single rivet in the wrong place.
09:14And further down the assembly line, another part will no longer fit.
09:17The consequence? Production stoppage instead of a smooth mega-manufacture.
09:24Up to a thousand cable ties per truck have to wrap around the right cables.
09:29Otherwise, it may be impossible to mount the engine or the cab on the chassis later on.
09:36Around 1,500 individual parts are installed in 210 operations over the next eight hours.
09:43From the simple, unadorned chassis to a state-of-the-art truck.
09:48Each of the trucks that rolls off the assembly line here in Ghent each day needs this part.
09:55The air pressure monitor.
09:57A piece of equipment essential for the braking system.
10:07These hoses carry the air.
10:09And because every truck is unique, a different combination of hoses are required for each model.
10:16A machine cuts a specific set for each truck from a choice of 20 kilometers of varying thickness of hose each day.
10:23They now have to be attached to the air compressor.
10:34But the variety of hose means no two fixes are the same.
10:39Keeping track here is critical or it can be very dangerous.
10:44If you make a mistake here, a vital part of the truck won't work.
10:49This device modulates the braking force, so it's crucial that I attach everything properly.
10:58There's a code here that tells me which hose has to go where.
11:03This has to be done right.
11:06Otherwise, the control system can lock up or the brakes fail.
11:10This is the heart of the entire brake system.
11:16The air compressor is now ready to be installed on our chassis.
11:21One of approximately 42,000 each year.
11:25Installation requires absolute precision.
11:29If a hose doesn't sit properly or has a kink, it will prevent the entire truck working.
11:36Done.
11:42All the small components are installed.
11:45But these steps could be carried out differently in the future.
11:49Greater efficiency.
11:51Fewer sources of air.
11:53In an adjacent building, they're working on the production operation of tomorrow.
11:57In the training center.
11:58The goal of these engineers, the digital factory.
12:03Mega manufacturing with 3D guidance on monitors directly at the assembly line.
12:08You can see here how it's inserted.
12:13As an instruction manual, you can zoom in and check how it's done in detail.
12:20The advantage is that you can zoom out to any level.
12:25Here, for example, you can move out a level and see where the cable has to be attached.
12:30Ah, fully automatic.
12:32Yeah.
12:34Pascal Mersrat is director of engineering and maintenance.
12:41And he wants to use this live data from the assembly line to improve workflow in real time.
12:48But that's not the most exciting bit.
12:51We call this here a virtual story.
12:53We want to use virtual reality to train the workers on new products.
12:58It gives them a better idea of what to expect.
13:04Right now, he's virtually inspecting a new truck.
13:11How it's built and what new features it has.
13:14This not only allows our engineers to familiarize themselves with the product,
13:19but more importantly, train our assembly line workers.
13:21This new technology will soon be rolled out in the main assembly area
13:31in order to build even better trucks in less time.
13:35The chassis of the FH.
13:38It's now ready for a significant moment in the megafactory.
13:42Production director Kuhn is present when the truck's frame is lifted into the air.
13:47I love this station.
13:59The chassis is now finished.
14:02Next, we turn it over and transport it to the automatic assembly line.
14:06From then on, the assembly line moves forward without stopping
14:10while we build the rest of the truck on the frame.
14:14All of the cables are now installed and after this station here,
14:18everything on the assembly line runs at a predetermined speed without a brake.
14:23This is when all of the large sections are fitted.
14:26The axles, the engine, the cab.
14:29Now it's time for the big parts.
14:30Approximately 1,800 kilograms begin the next stage of their journey.
14:42Positioned so that the truck's axles can be fitted.
14:48Everything is carefully coordinated in this truck megafactory.
14:51Just a few meters away, the most important part is about to enter the building.
14:57The engine.
14:59Manufactured at the main plant in Sweden and painted an iconic vovo green.
15:04With between 420 and 750 horsepower.
15:08Six cylinders which, when firing, can displace an eye-watering 16 liters.
15:12Next, the transmission, clutch and alternator are fitted to the powerful engine.
15:24Now fully assembled, it can finally be installed in the chassis.
15:31There's one engine attachment that Production Director Kuhn is particularly fond of.
15:36This is the iShift. Our pride and joy.
15:41A manual transmission in which various elements act in concert to make it easier to change gears.
15:55This is our special innovation. The heart of the engine.
16:00Very important to us.
16:01It's a patented development, inspired by the motor racing scene.
16:05Its purpose? Smoother gear changes and reduced stalling.
16:10The secret of the iShift transmission, it has two drive shafts that are connected to the engine via two clutches.
16:21When driving, the first gear is engaged via one shaft.
16:26The other shaft already engages the second gear.
16:29This immediately becomes active when changing gear, without the usual interruption.
16:40It prevents a loss of traction. A great help on hills.
16:47At the engine station in the main assembly building, the engine is waiting to be installed in the chassis.
16:59It's now lowered toward the assembly line from above.
17:03Below, the axles are already waiting to be connected to the drive shaft.
17:07And then, both will be attached to the chassis.
17:10From now on, the assembly line is fully automatic. The clock is always ticking.
17:25The engine has arrived, fully fitted and weighing it at 2,000 kilograms.
17:35This is one of the most important sequences at the plant.
17:39Everything has to fit perfectly.
17:46I guide the engine. That means I make sure it's lowered exactly into the chassis.
18:01We all have to pay attention that none of the cables get damaged in the process. It's pretty tricky.
18:11But it works.
18:14A wonderful sight for fans of pure, brute horsepower.
18:27Fantastic. We call this a marriage.
18:30We have three marriages in the factory.
18:33The axles with the chassis, the engine with the chassis, and the cab with the chassis.
18:36So this is a happy occasion for us.
18:41There are only three connections between the engine and the chassis.
18:45But that's enough.
18:54When I see one of our trucks on the road, see its engine, I say to myself,
18:59I did that. I installed that engine.
19:01It always fills me with pride when a Volvo truck drives by. It's a great job.
19:17A computer is used during the final stage of installation.
19:21The so-called Mont system for fixing the engine in position.
19:25Individually, according to the stored chassis number.
19:31The torque settings for the connections are stored in the computer.
19:36If these values aren't achieved, things can't progress.
19:40The computer control ensures that the connection is made correctly,
19:43and the customer can be satisfied.
19:50Now the chassis gets its fifth wheel.
19:53It will later connect the truck with the trailer.
19:55From here, it isn't much further until the final marriage in the factory is performed.
20:09Producing trucks on an assembly, this takes huge amounts of energy.
20:14On the outskirts of the Ghent plant, Pascal, director of engineering and maintenance,
20:18is on the roof of an adjacent building with some colleagues for an on-site meeting.
20:24Concealed from view on the roof is the source of the truck manufacturer's energy.
20:29An enormous solar plant, consisting of 15,000 panels.
20:48If we want to install the panel here, let's see how it can be done.
20:51The cable comes from down here.
20:59Ah, right. From back here. Understood.
21:04The Ghent truck factory was the first carbon-neutral automotive plant in the world.
21:09We use a combination of technologies.
21:21On the one hand, we have three of our own wind turbines,
21:25each generating two megawatts, and together producing 10,000 megawatt per year.
21:31Then there are our solar panels.
21:36We've installed 4,500 square meters of them.
21:41They produce 500 megawatt per year.
21:46This is supplemented by solar and hot water accumulators,
21:53and the purchase of green electricity.
21:56Apparently, a third of the parts used to build the trucks
21:59are made from recycled materials too.
22:02And there's also a biomass plant.
22:04Truck manufacture and carbon neutrality sound like odd bedfellows,
22:08but it feels good to be able to say that we, as a factory,
22:10are doing something for the environment.
22:12Yeah, absolutely.
22:14Back to our truck.
22:16Before it's marriage in the main building,
22:17the custom cab has to be fitted out, here at Cab Trim.
22:33The still bare cabs, which arrived from Sweden by train just this morning,
22:36wait in front of the building.
22:37It's now time to fit them out, each totally unique and different.
22:46300 workers in the Cab Trim Department transformed the bare shelves into fully furnished cabs.
22:55mats, wall panels, loudspeakers, all fitted by hand.
23:05And especially important, the bed.
23:1074 or 88 by 200 centimeters in size.
23:22Many customers request two fold-away bunks, one above the other, as in this case.
23:28Rubber seals.
23:39How important they are for the production operation in the huge truck factory will become apparent later on.
23:46Next to the cab assembly line, a handful of workers are dealing with the truck's electrical systems.
23:52From nearly a hundred different switches and plugs, they find the right ones for each truck and assemble the instrument cluster.
24:08The steering wheel pedestal is installed now too.
24:12They check whether all the connections are correct at a test station,
24:16and the instrument cluster is powered up for the first time.
24:22The area surrounding the steering wheel is especially important.
24:27The main concern is the electronics, but we check every rivet and screw,
24:32and whether all the connectors are plugged in as well.
24:37Modern trucks like the FH are full of computers.
24:41There's one element that's particularly important for the steering.
24:44It's a special electric motor on the steering column of the truck.
24:52Sensors dotted around the truck and in proximity to the driver transmit information to this motor 2,000 times a second.
25:00The result? It makes maneuvering less strenuous, assists in lane keeping,
25:06compensates for strong crosswinds, and even minimizes the impact of potholes.
25:11Volvo calls this dynamic steering.
25:14Silicone adhesive is now applied to the finished instrument cluster.
25:28A special hoist arm lowers the central element of the cockpit into the cab.
25:33A few screws and it's fixed in place.
25:48It takes five and a half hours for a cab to complete its journey through the cab trim building in the truck Mega Factory.
25:57And no two cabs are alike.
26:01One of the 300 women in the factory works in the final third of the building.
26:07Selene Kohlen from Ghent loves working on trucks.
26:12When I tell people I build trucks, they're always surprised because I'm not big and strong, but rather a small girl.
26:21But they're impressed by the fact, and that makes me feel good.
26:28The windshields, one of the few components in the Mega Factory installed by a robot.
26:35First, it measures the exact dimensions of the cab.
26:39Then it grabs the appropriate windshield, applies silicone, and installs it with millimeter precision.
26:57The unit costs two and a half million euros.
27:01It's important that this task is performed by the robot.
27:04We need absolute precision here.
27:07This is vital in order that the windshield sits securely and is windproof.
27:12But despite this, it doesn't always work flawlessly, as we'll soon see.
27:18Time for the seats.
27:20There are 12 different models to choose from, all designed for comfort and durability.
27:25Now comes the steering wheel.
27:27Every one individually adjusted and mounted with this torque wrench.
27:30This is followed by the doors, side view mirrors, and labels.
27:45But the cab can't be mounted on the chassis just yet.
27:49We'll find out why in a minute.
27:51Many operations in the Mega Factory involve strenuous manual work.
27:59But the tasks this employee performs just using muscle power are soon to be made easier.
28:06The truck manufacturer is testing a new technology in the cab trim section.
28:11Exoskeletons.
28:12I don't think this here is sitting right yet.
28:20I don't think you need to move your arm so far back.
28:25Hold it up again. Now it's activated.
28:31The mechanical lifting aid developed in the USA should lighten the load on workers.
28:39There are some tests that involve workers lifting up to and above shoulder height.
28:46The exoskeleton helps them do this.
28:49For example, when I'm attaching the roof strip and take that tool.
28:54The tool from up there.
28:57Above my shoulder.
28:59Yes.
29:00Operator Edouard Dumont gets started.
29:04The braces of the device reduce the weight of the lifted parts by almost seven kilograms.
29:13It doesn't make Edouard faster, but he'll have fewer shoulder and back problems later in life.
29:19Actually, it is quite easy, but you have to get used to it.
29:30During the first three weeks, I had to make big adjustments to my work rhythm and the order of my work steps, too.
29:36A robot wouldn't help here.
29:39A robot is an option where you have to perform the same task over and over again.
29:50That can be automated, but that's difficult to do in our factory because we have far too many truck and cab variants.
29:56We need the flexibility offered by our workers.
29:59We're a factory with humans and need our operators.
30:01So, I believe that an exoskeleton is better than a robot.
30:09Workers like Edouard are testing the technology at five stations in the plant.
30:15If the results are positive, it could become commonplace here.
30:20Back to our cab.
30:22Like every cab in the truck factory, custom-built according to the customer's wishes.
30:26Emre Tamiz checks whether all the optional extras are installed.
30:35There's a microwave installed in this truck.
30:38This is practical for the driver.
30:40He can use it to warm up or defrost things.
30:43The microwave has an LED light, three power settings and a defrost function.
30:49It has a 17-liter capacity.
30:51And down here, we have a 33-liter fridge.
31:00It can also be used as a freezer.
31:06The seat here has air suspension.
31:09You can adjust it to any height, which I think is a good feature as you don't feel the potholes and bumps as much.
31:15There's a touch screen with navigation system and popular apps like the Dynafleet system.
31:32This allows the driver to monitor all his trips and activities and store them for two years.
31:36If I were a truck driver, I'd feel really comfortable here.
31:42There's plenty of space, you can stand upright, the bed is great and there's loads of space to store things like clothing and food.
31:51There's more storage space up here too.
31:53And there's a mirror for putting on makeup or shaving.
31:56You can do everything in here.
31:57This custom mass production operation is made possible thanks to a sophisticated logistics system.
32:07But something is still missing.
32:09The cab is now fully assembled and it could now move on to final assembly.
32:15But this one is going to be subjected to a water test.
32:18Sam here will take it over to the water testing bay and check if there are any leaks.
32:27The cabs are chosen at random and team leader Gunther de Klerk is a little nervous before each of these tests.
32:35We occasionally have problems with the robots resulting in a leaky windshield or roof hatch.
32:40Roof antennas, which don't sit securely enough and allow water to get in, can be a problem too.
32:50Fingers crossed, that shouldn't happen normally.
32:54If the cab has a leak, they have to test the 10 preceding and the 10 following cabs too.
33:01This slows down production in the entire factory significantly.
33:05A 15-minute drenching, then it moves to the yard to be manually inspected with a flashlight.
33:14If tester Kenfang Haluva discovers even a small puddle, production will be halted.
33:24But everything's fine this time.
33:27The hope for stamp of approval.
33:30The cab is okay, no leaks.
33:32It can now be brought over to final assembly.
33:35They assemble approximately 200 cabs per day, depending on the order book.
33:45Ours is now ready to be mounted on its chassis in the main assembly building.
33:52The heart of the truck factory.
33:54Our chassis, together with its engine, is now heading toward the climax of the production operation, the cab drop.
34:01The cab drop.
34:13Thirteen hundred kilograms approach the chassis, centimeter by centimeter.
34:18Everything has to fit perfectly.
34:27The next cab will arrive in five minutes.
34:42Full concentration is required.
34:44Two bolted joints at the back, and two at the front.
34:51Then, the marriage is over.
34:54And the next one begins immediately afterwards.
34:57Our cab is lowered onto our chassis.
35:02Every time we have visitors to the plant and we watch a cab drop, they say, now that's a truck.
35:18It's a really important station for us when the cabs join the chassis.
35:21It's now recognizable as a truck.
35:28Following the marriage, the truck is nearly finished.
35:32But something is still missing.
35:34Something from the fitting center.
35:36The truck plants huge tire warehouse in Ghent.
35:42One of the biggest in Europe.
35:44Over 550 tread patterns and around 12,500 tires covering an area of 13,000 square meters.
35:53A suitable tire to meet every customer requirement.
35:57And the matching rims too.
35:58There are a hundred types of rims alone.
36:08Special robots mount the tires on the rims.
36:12167 an hour.
36:14It takes 63 seconds for each one.
36:17Faster than a human could do it.
36:19From here, the tires now head to our truck in the main assembly building.
36:30A large five-way torque gun tightens all the lug nuts at the same time.
36:36This saves time and ensures that no nuts get forgotten.
36:40The diesel tanks can hold up to 900 liters of fuel.
36:44And every customer gets to choose the right one for his truck.
36:49Filling with diesel, oil and AdBlue.
36:55The final operation in the assembly building.
36:58One of approximately 42,000 trucks each year is now heading for the finishing line in the Ghent Megafactory.
37:20It's a very important station.
37:22Here, all of the hoses are pressurized for the first time and the power steering is tightened.
37:27This is the crucial moment when it will become apparent whether there are any leaks in the lines.
37:32This is an important test after filling the tank.
37:35If the truck can then drive off the line, we can have a big celebration.
37:38For us, it's a back party when you drive off the line.
37:43Production director Kuhn wants to start up our truck personally.
37:47Super, perfect, a good truck.
37:53One like this rolls off the production line every 10 minutes.
38:06It's taken eight hours to build the FH.
38:12Starting with the chassis.
38:14With all the cables, hoses and air pressure regulator.
38:18Then the axles and drive shaft.
38:21Followed by the engine with a smooth I-shift dual clutch transmission.
38:25And finally, the cab with the electric motor for the dynamic steering system.
38:33And one of Europe's most popular trucks is complete.
38:38But not every fully assembled truck is exactly how the customer wants it.
38:45That's where the mega-manufacturer's Market Adaption Center comes in, fulfilling special requests.
38:58Specialists like Daniel De Koenig are responsible for this.
39:02And the most frequent requested? Cosmetic changes.
39:06Remove the PA15.
39:09It's to be painted in color 98717.
39:11Then PA20-60 in color 2705.
39:20The customer wants to have specific parts of the vehicle in other colors.
39:24So Daniel's colleagues dismantle the finished truck once again.
39:29Time-consuming.
39:31But indeed simpler than changing the production workflow in the main assembly building.
39:36Meanwhile, line manager Daniel has to visit the paint mixing room.
39:41The cab of another truck has to be completely repainted.
39:45Good morning.
39:47Morning, how's everyone doing?
39:49Didier, can you finish mixing the color so we can paint the cab please?
39:56The precise mixing ratio is stored in the computer.
40:02Almost 900 colors are in stock, making countless hues and variations possible, including loud ones.
40:11We once had a customer who wanted everything in pink.
40:17Chassis in pink, cab in pink, all the plastic parts in pink.
40:21This was our pink lady, something I'll not forget in a hurry.
40:24The desired shade of black is mixed. Five liters are sufficient to paint a cab.
40:34The spray job is done manually by small teams of workers.
40:39In the three paint booths, they can repaint practically everything on the truck according to the customer's wishes.
40:46Even the entire chassis, if the customer so desires.
40:51In a few hours, the yellow cab will look like this one here.
40:55Black is popular, but line manager Daniel says colorful is making a comeback.
41:01More and more customers nowadays want parts of the truck in different colors.
41:06This in yellow, this in red, this in blue.
41:08We're sometimes rather surprised about the combination of colors.
41:13But their motto is, anything is possible.
41:19Back from the market adaption center to main assembly, our truck still isn't ready for delivery.
41:29What happens following production is as important as the assembly itself.
41:35A thorough test.
41:38The truck will now be put through its paces in the testing bay.
41:51The dyno.
41:56Acceleration.
41:58Braking power.
42:00Lights.
42:01Tester Christophe Tremory logs into a computer that's programmed with a test procedure for every truck.
42:14Windshield wipers.
42:19Indicators.
42:21Headlights.
42:23Horn.
42:24And the best is yet to come.
42:25The bit I enjoy most is driving and accelerating.
42:32When I started, it was difficult to keep the truck centered.
42:36But after a few weeks, I knew the ropes.
42:38Does he still start off carefully and stay in the lane?
42:45First at 30 kph instead of 80 to warm up.
42:58Then Christophe steps on the gas.
43:01Will the truck perform as expected?
43:03As expected.
43:07Not far from the dyno at the end of the main assembly building, there's another building for testing the trucks.
43:14With another focus.
43:16The audit.
43:17He is one of the factory's elite testers.
43:22David Peens.
43:2435 years old.
43:25And at Volvo for 12 years.
43:272% of the trucks have to undergo an intensive test with him.
43:32This time, it's the FH16.
43:35The premium model.
43:38David's eagle eyes spot something that isn't so premium.
43:48There's a scratch on the indicator here.
43:55When I take the glove off, I can feel it.
43:58I have to report it so it can be replaced.
44:06Hardly detectable.
44:08Even for the camera.
44:12But David isn't just concerned with the visual appearance.
44:15He will be the first to drive the truck out of the factory.
44:36750 horsepower on its maiden trip.
44:39On public roads.
44:43Under realistic driving conditions.
44:54In order to test things that can't be tested on the dyno.
44:57The red light at the front there is the collision warning system.
45:12If you drive too close, the red light comes on.
45:17You can set the distance and decide whether you'd rather be closer or further away.
45:21The collision warning and lane keeping systems.
45:23These are the two most important things I test.
45:25I also listen to whether the engine is making unusual noises.
45:28Or anything in the cab is rattling.
45:29David steps on the gas.
45:30He has, without doubt, one of the most sought after jobs in the factory.
45:31For me, it's a childhood dream come true.
45:32The car is a boy.
45:33The car is a boy.
45:34The car.
45:35The car.
45:36I'm not going to run the car.
45:37The car is a man.
45:39The car is a man.
45:40The car is a man.
45:41It's a man.
45:42The car is a man.
45:43anything in the cab is rattling. David steps on the gas. He has, without
45:51doubt, one of the most sought-after jobs in the factory.
45:57For me, it's a childhood dream come true. When I started at the factory, I kept
46:05hearing about the test department and what they do here. I wanted to do that
46:10too. And now my dreams come true. I'm really happy in my job.
46:27Test driver David drives for 50 kilometers. Aside from the scratch on the indicator, the
46:33truck is flawless. Back to the dyno, the test track in the main building.
46:40Tester Christoph brings the FH up to full speed. Can it reach the required 80 kilometers per hour?
46:47Yes, it can.
46:49This truck can get up to 90. Others can go as fast as 100. Or 120.
46:57Because every truck leaving this factory is different. Mega manufacturing individually
47:03tailored to customer requirements. Test complete. And passed.
47:12The time has come. Our Volvo FH is ready to be handed over to the customer.
47:18We are ready to be handed over to the customer. And we are ready to fulfill their calling as
47:28powerful transport machines somewhere on the roads of Europe.
47:32They are all built in the Belgian town of Ghent, at a mega manufacturer, one of the largest
47:52truck plants in the world.