Supercar.Superbuild.S01E04.Lamborghini.Huracan
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00:00It's the most famous bull in the automotive world, a brand born from anger.
00:08Ferruccio Lamborghini was pissed off.
00:11And synonymous with high-performance exclusivity.
00:13They've been known as the company that makes wedgie cars that go really fast in a straight
00:18line and that's it.
00:19For over 50 years, Lamborghini has handcrafted high-end Italian supercars.
00:26The whole point of a Lamborghini is to look and to sound outrageous.
00:31Their most popular model is the best-selling Italian supercar in history.
00:36The Gallardo was the most successful Italian supercar of all time.
00:40The Gallardo absolutely was the car that put this company on firm ground.
00:46Now, the Gallardo needs to be replaced.
00:50For the model comes once a decade for us.
00:52So it's a very critical time, a very demanding time.
00:56One misstep could spell disaster for the marque.
00:59We have only one bullet in our gun and if we miss, then for a decade we are wiped out.
01:04It's an Italian bullet called the Lamborghini Huracan.
01:19The aeronautically-inspired silhouette blasts from 0 to 100 km per hour in just two and
01:32a half seconds.
01:33It has a top speed of 325 km per hour, one quarter the speed of sound and the weight
01:44of an entire automotive brand hinging on its success.
01:48The Lamborghini Huracan is the newest machine from the house of the raging bull,
01:53one of the most famed and feared marques in the automotive world.
01:58Yet the brand owes its creation to two men and a myth.
02:02In post-war Italy, industrialist Ferruccio Lamborghini is making a fortune building tractors.
02:08It's a booming business in the agrarian region of Emilia-Romagna,
02:12a place where farming has ruled for centuries.
02:15In 1960, his company sells over 400 tractors per month.
02:19The wealthy industrialist buys a Ferrari 250 GT.
02:23But, as the legend goes, the car has a problem with its clutch.
02:27Ferruccio Lamborghini bought a Ferrari, it broke, he went back over to Enzo,
02:31screamed at him and said, you know, I can build a better car.
02:34This was started in anger.
02:36Nothing looks like a Lamborghini, nothing performs like a Lamborghini.
02:40They're a very unique brand.
02:42Ferruccio Lamborghini immediately sets his gaze on Enzo's empire.
02:46In 1963, he purchases a large plot of land 25 kilometers from Bologna, Italy,
02:52in the town of Sant'Agata Bolognese,
02:54with only one goal, manufacturing cutting-edge Italian supercars.
02:59Sant'Agata is a little town that you definitely never would have heard of,
03:03if it weren't for the fact that there are Lamborghinis driving all up and down these roads like maniacs.
03:08Three years later, in 1966, Ferruccio puts both Enzo and the world on notice.
03:15He introduces the Miura.
03:18The mid-engine two-seat V12-powered sports car
03:21is widely considered to be the world's first true supercar.
03:25They were very hand-built. These were kind of craftsman pieces.
03:28You were lucky if it started, and if it didn't explode into flames, bonus.
03:34In 1974, the brand takes the next step
03:37and reinvents the very supercar genre it helps create.
03:43Introducing an edgy, angular machine called the Countach.
03:46It lays the groundwork for all modern Lamborghinis.
03:49The Countach was described as the holy desire to build a car with a single line,
03:55and the single line was the silhouette of this car.
03:57And we are still playing around this initial concept.
04:00While the brilliant looks and Italian V12 engine captivate auto fans,
04:04the machines are unreliable and poorly made.
04:08For the next 35 years, the brand lists from brilliancy to bankruptcy,
04:13while at the same time crystallizing a supercar mythology.
04:17Lamborghini has gone through a number of owners over the years.
04:20They've had big ups and downs in their financial situation.
04:23It's been really rocky.
04:25In 1998, Audi purchases the brand and dramatically changes its fortunes.
04:30The German automaker's first task is to re-inject life into the company.
04:35Lamborghini probably was closer to ceasing to exist than we'd like to think.
04:41In 2003, the masterstroke, the Gallardo.
04:46A smaller, lighter, less expensive V10-powered supercar.
04:52The Gallardo was, let me say, it's an entry-level supercar.
04:57The machine's lower price tag opens up new markets to the brand.
05:02The number of people on the planet who can afford these cars is pretty small.
05:06And you do need to be careful that not everyone who lives in those neighborhoods has one.
05:12One year after putting the Gallardo into production,
05:15Audi taps Stefan Winkelmann to be the company's new CEO.
05:19It was one year after the Gallardo was introduced.
05:22The company was smaller, we had less people.
05:24Winkelmann's first order of business is to transform the automaker into a modern brand.
05:29Once the Gallardo happened, Lamborghini started making real cars.
05:33Under his watch, the company has gone from pretty dire straight to today,
05:38where they're stronger than they've ever been and selling more cars than they've ever sold.
05:42In 2002, the year before the Gallardo, the brand sells just 424 cars.
05:49After the Gallardo, they sell 1,305.
05:56It was a starting point. We all realized it at that stage.
06:01By 2007, the market experiences a 467% sales increase,
06:08selling a record 2,406 machines.
06:12This is without question the most commercially successful era of Lamborghini.
06:16They've never been as financially stable.
06:17Financial stability keeps the brand on solid footing, but doesn't make them ordinary.
06:22In the real world, seeing a Lambo is a very rare event.
06:26In the entire world, there's less than 50,000 Lamborghinis.
06:29If there are 71 million cars produced in the year 2013, we had a bit more than 2,000.
06:37In its 50-year history, the house of the raging bull has built close to 30,000 cars.
06:43Not only was the Gallardo the most successful Lamborghini ever made,
06:47but in its 10-year run, it accounted for more than half of all Lamborghinis ever made.
06:53We kept it fresh and updated almost a decade.
06:57A decade is a very long time in the realm of the supercar,
07:01and cutting-edge tech ages.
07:07All the company was under pressure, and there were several meetings
07:10because when you start a new project, you try to understand what is needed.
07:15For Lamborghini, the stakes are clear and dramatic.
07:18The Gallardo keeps the brand in business.
07:21I imagine everyone at Lamborghini was very cautious.
07:24If its replacement fails, it spells disaster.
07:29With the task to be able to replace the Gallardo,
07:33but to increase the success of the car,
07:36and trouble from the beginning in order to think what can be better.
07:41Repeating the Gallardo's success is a tricky proposition.
07:44In 2010, at the tail end of a worldwide depression
07:48that sees Lamborghini's sales drop 45%,
07:52the brand decides it's time to replace an icon.
07:55It's creating something which is state-of-the-art,
07:58and pressure maybe, but a lot of expectation.
08:01My briefing to the team in general four or five years ago was very easy.
08:07But turning it into reality is hard,
08:10because it must equal the Gallardo's success.
08:16We developed a car which has to have an outlook of almost another decade,
08:20so you have to think forward, and this is one of the most difficult things.
08:24To devise a revolutionary machine,
08:26the Lamborghini team focuses on three levels of performance.
08:30There are three points which are key.
08:32One is acceleration, the other one is top speed, and then handling.
08:36In the past, number one was always top speed.
08:39For decades, top speed was a selective club.
08:42Only a few machines could crack 320 km per hour.
08:46But now, Lamborghini's technology is evolving.
08:49Accelerating, and having the easiness in the corners,
08:52and this is done with the power-to-weight ratio.
08:55Finding that balance is tricky when you're a niche manufacturer.
08:58The challenge for a small manufacturer is the amount of money,
09:02and the brains you put in place.
09:04The brand not only banks on its heritage,
09:06but also its unique Italian design aesthetic.
09:09The people which are living here, they have a lot of money,
09:12they have a lot of experience,
09:14they have a lot of knowledge,
09:17The people which are living here, they have a certain attitude,
09:20and Italians, they are known for style.
09:23I think that Italy is one of the few ones which is creating those type of cars.
09:27The process of designing the Gallardo replacement starts with a basic set of rules.
09:33We try to give simple rules to the designers,
09:36which the first one is that the design has always to be very different,
09:40but you know that it can't be anything else than a Lamborghini.
09:43The second thing is a form always follows function,
09:46so there is no things which are pimped up or made beautiful
09:50just to show something which is not functional.
09:52The third one, and our inspiration is always coming from the aeronautic industry.
09:59This car was inspired by the stealth fighter.
10:02They loved the angles and the purpose and the look of the F-22 and the B-1,
10:08all these really neat airplanes.
10:14Filippo Perini is the man entrusted with bringing those stealth fighters for the road to life
10:19inside of the Lamborghini Centro Stile design studio.
10:23This room is the place where the new Lamborghini, the idea and the concept grow up here.
10:28Perini is one of the most outrageous automotive designers in the world.
10:33When we start to work, we start to speak about cars,
10:36and this is completely crazy.
10:38I think that Lamborghini is built by a man for challenge.
10:43It's something that we have to respect, and in the daily job, this is very tough.
10:47For Perini, that willingness to get better starts at an early age.
10:51He pens his first car at the age of two.
10:54This is my mother. I never take care about stuff like this,
10:57but my mother, yes, she was really attracted by my inclination to do sketches
11:02and to send sketches to the magazines.
11:04This is a magazine that was used to show artwork made by children,
11:08and I was one of them, and this is a Lamborghini.
11:12In 2011, Perini improves on the past when he pens the Aventador,
11:17Lamborghini's newest flagship supercar.
11:20You can see a lot now in aeronautics that there are many planes that are not so soft,
11:24first of all because they have to be stealth.
11:27The styling echoes the lines of the legendary Countach, Diablo and Murcielago,
11:32but also radically pushes the brand into a new direction.
11:36Every bit of Italian design that's successful has a little bit of kitsch in it, too.
11:40It's a little bit too far.
11:41If you look at modern Lamborghinis, you see it's probably one step too far.
11:45But isn't that the whole point of these cars?
11:50The design we are building is driven by the silhouette.
11:53This line is in the middle.
11:56In the Huracan, it's a single one. It's monobody.
12:03My guys, my designers, the engineers, they want to do better.
12:08They want to at least be a bit above what the others have done.
12:13The process starts with an internal design competition.
12:17When we do a competition for a new product, we have at least two main goals.
12:22One is to do a beautiful car, and the second is to be the people that are winning the contest.
12:28It's always very important to be present in this game and to be a winner.
12:33That contest could very well determine the survival of the brand.
12:37It was very important for them to really get this car right.
12:41When you're pushing the boundaries of contemporary design,
12:44getting the car right means standing up for your vision.
12:47Probably the beauty of the design job is, let me say, 10% of the game.
12:53The rest, 90%, is to save what you have done in the beginning of the project.
12:57Designing for the future keeps the brand relevant.
13:01At the end, you cannot follow the trend of the market.
13:04Otherwise, you cannot be a winner.
13:06That future unfolds in a very 21st century way, completely digital.
13:11In a land of hallowed artisans, Lamborghini no longer uses clay to design their cars.
13:18It's a very traditional business to design a car.
13:21You sketch it, maybe these days you do some computer renderings,
13:24but you build a clay model, and you shape it by hand,
13:27and you really make this so you can stand back and look at it.
13:30Lamborghini doesn't do this anymore.
13:32They design the entire car on a computer.
13:35It's very, very normal for me now to judge a new design in a monitor of 21 inches.
13:40It doesn't matter. And after we print the model, it doesn't matter the scale.
13:45It's an incredible process, and it gives them a lot of freedom to make little changes,
13:48and they can do it immediately.
13:52This is the process, because it's much more lean.
13:55It's much more driven by desire.
13:57Behind the monitor, there is always a designer.
14:00If you don't switch on the computer, it's doing nothing.
14:03This process is driven by the brain of a man.
14:05The machine is not only made by man, but lusted after, too.
14:10The sex appeal comes from different...
14:12No, we cannot say. It's porn. It's not only sex. It's beautiful.
14:17That beauty starts inside one of the most revered supercar factories in the world.
14:22I'm tired that it's the hometown of Lamborghini,
14:25and for us it's special because the brand needs roots.
14:29Arriving at the Lamborghini factory for the first time is really a neat experience.
14:33You're driving, and you're passing all these farms, and there's nothing,
14:36and then you come into this little town, and then here's the Lamborghini factory.
14:40And if you get back into the factory itself, it's still the factory that it was 60 years ago.
14:45It's still the same building. They've added more buildings, but it's still there.
14:48The factory is located in the heart of Italy's Emilia-Romagna region,
14:52otherwise known to automotive fans as La Terra di Motori.
14:57Emilia-Romagna, it's called also La Terra dei Motori,
15:00so it's something that a lot of super sports car brands are here.
15:06In this area, there is a kind of Bermuda triangle of performances.
15:11If you think about Ducati, Ferrari, Pagani,
15:13there is a concentration of needing horsepower.
15:19I don't know why there are so many companies, so many car designers, so many car fans.
15:26I have some friends here, they cannot speak about normal, they are only speaking about cars.
15:32That speed comes together on hallowed supercar ground.
15:36Today's Lamborghinis are assembled in the very same building that Ferruccio used in the 1960s.
15:42It's been heavily modernized. It's clean and well-lit and spacious.
15:47It's not a little dusty old shop anymore. It's a fully modern factory.
15:50That factory 20 years ago didn't look as organized as it does now.
15:54It was wires everywhere, people tripping over stuff,
15:57fighting, throwing cigarettes and espresso at each other.
15:59I mean, you can imagine, it was just nuts.
16:02The man responsible for Lamborghini's modern factory is Ranieri Nicoli.
16:07He's the director of production at Lamborghini.
16:10I'm in charge of all the things you are seeing here,
16:13so all the assembly of the car and also the logistics of the parts
16:17and all the assembly of the car in Lamborghini.
16:20It's Ranieri's job to get the factory ready for Huracan assembly.
16:24It's really challenging. When a new car is born, it's really something complicated
16:29because you have to imagine that a car is made by something like 2,000 parts.
16:34All this activity all together is really complicated.
16:38Coordinating all those parts takes place on 22 stations
16:42that produce just 13 cars per day.
16:45We are at the starting point of our assembly line, composed by 22 stations.
16:50In each station, we are starting to assemble some parts
16:53in order to start from naked cars.
16:56All 22 stations are run by artisanal mechanics.
17:00Craftsmanship is the big word in our factory.
17:03We have two assembly lines, and these lines are going slower
17:07than a highly automated factory.
17:10It's a craftsman's approach to car building, based on perfection.
17:15We have more people doing the assembly,
17:17and this is craftsmanship, but also the love of the people.
17:20Typically, the line moves every 34 minutes.
17:23This is a combination between craftsmanship but also technology.
17:27The car has to be unique for each customer.
17:31That quality has a truly national identity.
17:35Lamborghini, for Italy, means cars.
17:38It means passion, it means speed,
17:40and this is something that for Italian guys is the best place.
17:43Building an Huracan starts with the machine's body entering the line.
17:47So basically, here we are starting to assemble the new Lamborghini Huracan.
17:52This is the first station.
17:54Bodies are painted off-site in one of 19 colours
17:57and arrive ready to hit the ground running.
17:59Only at Lamborghini, the onus isn't on speed but speciality.
18:04It's not an assembly line running through as quickly as they can either.
18:07There's only a small number of workstations.
18:10It will take months to ramp up production on the new Huracan,
18:14a small price to pay when you're betting your brand
18:17on a platform that needs to survive for a decade.
18:22We are in the starting phase of production of the Huracan,
18:26so our production is quite low because we are starting to produce the first car.
18:30After you develop a car, then you have all the parts which are coming together
18:34until it finally fits with the puzzle and with the quality we want.
18:38And then we ramp up.
18:40High-speed manufacturing at Lamborghini still isn't all that fast.
18:49An Italian factory is kind of unique
18:51because the Italian cars that you think of are your supercars,
18:56are your Ferraris and Lamborghinis.
19:01When you get to cars like that, they're being built low-volume.
19:03It's a slower process.
19:05It will take two days to build an Huracan once the factory hits full production.
19:10You know, an Italian car factory, these people are passionate.
19:14They want to be there. They are true believers in the brand.
19:17They really are passionate about the product.
19:19Like the design team foregoing clay,
19:21Lamborghini tests the process of putting the Huracan together
19:24with a pre-production series of machines.
19:27So we are doing this job first with the electronic file.
19:30We try to figure out how we can assemble the parts
19:33and at the same time we try to design the line in order to say,
19:37OK, in this station we will assemble this part,
19:39in the other station we will assemble the other part
19:41because we can't assemble all the parts without the right sequence.
19:45Finding the correct installation sequence is just one dimension.
19:48Ergonomics and tooling concerns are important too.
19:51Correct means ergonomic,
19:53so the worker doesn't have to feel the effort to do this all day.
19:56And also possible, so all the tooling we need,
19:59screw and other things, has to fit and not to have clash
20:02in order to assemble the parts.
20:04All the planning in the world still requires putting it into practice.
20:08So all this activity is done before
20:10and let's say some months before the start of production.
20:14Pre-production starts by checking the quality of the parts
20:17arriving at the factory.
20:19We have to check together all the parts coming from these 200
20:23and more suppliers all over the world in this phase.
20:26Those parts are sorted in various areas of the factory
20:29and then placed on carts that head directly to the line.
20:33We have 22 stations and we have to assemble 2,000 parts.
20:36You can imagine how many parts per station we should manage.
20:40And all the parts are coming with boxes.
20:42So every worker in each station has only the parts
20:45they need to assemble for one cart.
20:47They don't have to choose, they don't have to find the right boxes.
20:51You receive some trolley like this, in a way, for example,
20:54this is a part which is basically already with support
20:57old with the pictures.
20:59Some of those parts arrive at the early stations on the line
21:02where the Orican's hybrid chassis starts to take shape.
21:07We are using not only aluminium but also carbon fibre.
21:10And we are using carbon fibre where we need more strength.
21:14Because the carbon fibre has a unique combination
21:17between light weight and strength.
21:20So we are using in an intelligent way the carbon fibre
21:23when we need more strength for the car.
21:28Carbon fibre really is Lamborghini's specialty.
21:31It's what they've really hung their hat on.
21:33It's a cutting-edge material for a very high-tech machine
21:37that needs to succeed for Lamborghini to stay alive.
21:44In Sant'Agata Bolognese, the pressure is mounting
21:47as Lamborghini attempts to replace their best-selling machine.
21:52The key to their success comes down to a very earthly material.
21:56Carbon.
21:58A basic element finding new life
22:01inside of the state-of-the-art Lamborghini carbon fibre facility.
22:06A couple of decades ago, Lamborghini decided to look into carbon fibre.
22:09A lot of car companies looked at it, decided it was too expensive
22:12and moved on.
22:14We have an expertise of more than 30 years
22:16in the research and development of carbon fibre material.
22:21Lamborghini kept with it, they kept researching it
22:23and today they're on the leading edge of carbon fibre technology.
22:26Like an Italian model,
22:29the brand is obsessed with weight and weight reduction.
22:33The cars are getting heavier and heavier over the decades.
22:37Due to different reasons, safety, active and passive safety,
22:40comfort, all these things.
22:44Weight is a supercar's enemy because it reduces speed.
22:49Weight-to-power ratio is a really key factor in success for the future
22:53and weight reduction is more important of horsepower increase.
22:57If you reduce weight from the car,
22:59you will perceive in every single moment
23:02when you accelerate the car, when you brake the car,
23:05when you go in a tight cornering
23:07and you really perceive the handling behaviour of the car.
23:10The key word for us is mainly carbon fibre,
23:14which is a very light and stiff material.
23:16They're building most of the car out of at this point
23:19and they're exploring ways to use carbon
23:21to create structures that are light and stiff.
23:27That exploration results in a brand new chassis
23:30that's 10% lighter than the Gallardo's,
23:33but 50% stiffer.
23:35In a company like Lamborghini,
23:37we can really also experiment new material
23:39because we can offer something special.
23:42To give an example, a kind of composite material
23:44that we call forged composite
23:46and this kind of fibre is exactly what is used also
23:49in the golf club of Callaway.
23:51A supercar sharing carbon technology from a golf club
23:55sounds surprising.
23:57It shouldn't be, thanks to a very unique agreement
24:00between three very diverse organisations.
24:03It's not unusual for car companies
24:05to look out to other industries
24:07to see where they can find new materials, new processes,
24:10but Lamborghini has been so focused on carbon fibre
24:12they've really reached out to places you wouldn't expect,
24:15Boeing, the University of Washington and Callaway Golf Clubs.
24:18The weight can affect everything.
24:20It affects your swing, it affects how fast your car can accelerate.
24:24The Lambo's strategy for speed
24:26comes into focus on the new Huracan.
24:29The machine features a hybrid carbon fibre
24:32and aluminium chassis,
24:34with the front and rear sections
24:36made entirely from lightweight alloys,
24:39while the occupant safety cell
24:41is completely made from carbon fibre.
24:44The entire hybrid chassis weighs just 200 kilograms.
24:48The challenge is the joint
24:50between carbon fibre and aluminium
24:52in which it has to be designed
24:54to resist all the stress we have in the car
24:57during the use of the car.
24:59Unlike most car factories,
25:01at Lamborghini they install the interior
25:03before the drivetrain.
25:05They install the carpet,
25:08the centre console,
25:15and the dashboard.
25:24The gauges in front of you are not gauges,
25:26it's an LCD screen.
25:29You have one big screen in front of you
25:31that does everything.
25:33You can configure it to have a big tachometer
25:35or a big speedometer.
25:37It's very driver-focused.
25:40While mechanics continue to assemble the new Huracan,
25:43in another part of the factory,
25:45artisans handcraft Lamborghini interior pieces.
25:48Just 50 metres from the Huracan line,
25:51hides of leather are lined up.
25:53The hides arrive at the factory
25:55already treated and coloured.
25:57The range of colour options
25:59is only limited by imagination.
26:02Master leather workers inspect
26:04each hide for imperfections.
26:07A computer-controlled cutting machine
26:09optimises the number of panels cut from the material
26:13before craftsmen mould and secure
26:15the leather to the trim panels.
26:19Then they stitch them together one by one.
26:23Choose the upgraded interior package
26:25and each artisan will use 30 metres worth of thread.
26:29Finally, finished leather pieces
26:31head to the line.
26:33Station 11 is perhaps the most famous location
26:36in the factory,
26:37where the Lamborghini V10
26:39is prepped for installation.
26:41Here we are in one of the most important
26:43stations of the line,
26:44in which we assemble the engine,
26:46so 610 horsepower,
26:49with the gearbox.
26:50Lamborghini's tradition
26:52is a naturally aspirated engine.
26:56Which has an outstanding torque
26:58already at very low revs.
27:02The weight of that tradition
27:04rests on the shoulders of Stefano Mazzetti.
27:07Here in Lamborghini,
27:08we have the responsibilities of the powertrain,
27:11so it means mainly transmission and engines.
27:15Making it work together
27:16means creating a one-of-a-kind V10 engine
27:18called the LP610-4.
27:22The V10,
27:23it is really a compact engine,
27:25but with really very high displacement,
27:295.2 litres.
27:30It is a naturally aspirated,
27:32so very emotional engine.
27:36It is really a unique piece of engine art.
27:40Italian high-performance art
27:42that's sub-assembled on a jig
27:44next to the main line.
27:46Basically we assemble
27:47the heart of the car inside the body.
27:52The engine is a 7-speed LDF transmission.
28:02They install the engine to the LDF,
28:04or Lamborghini Doppia Frisione,
28:077-speed transmission.
28:10It is a super sport double clutch.
28:12The gearbox is really compact
28:15because we wanted to make it really shorter.
28:18A double clutch transmission
28:19is essentially two traditional clutches
28:21in the same case.
28:23One stack contains first, third,
28:25fifth and seventh gears.
28:27The other holds second, fourth and sixth.
28:30When a driver accelerates in one gear,
28:32the other stack engages the next gear in preparation.
28:37Shifting gears takes just a few hundredths of a second.
28:45Installing the transmission to the engine
28:47takes only a few moments longer.
28:50This gearbox and engine
28:51then is going to the car
28:54in the so-called marriage station.
28:56The marriage looks almost effortless,
28:58but installation has to be highly accurate.
29:02We have to be really precise
29:03because if you can see the car
29:05and the space between the chassis
29:07and the engine, that is really narrow.
29:09We are talking about even less than a millimetre.
29:11So our work has to be precise
29:13to avoid any collision.
29:16The tight margin for error
29:17is all due to the distinctive
29:19mid-engine design layout.
29:25This is a unique challenge for Lamborghini
29:27to put the engine on the back.
29:31They install the oil tank,
29:36the airbox
29:41and the driveshaft.
29:46To move the machines around,
29:48Lamborghini employs a variety of carrier systems.
29:52When the car is just a body,
29:54we have basically a carrier system
29:56which is kind of taking the car from the bottom.
30:01And then the working needs to have
30:03the car higher or lower
30:05can adjust the position of the car.
30:08Then when the car is on the back,
30:10we have the engine.
30:12This is the position of the car.
30:15Then when the line is turning to the second part,
30:17we have this kind of carrier
30:19which is taking the car from a hook
30:21because we need also to work
30:23on the bottom of the car.
30:25The first stop after a new Huracan
30:27is picked up by the massive hook
30:29is station 12,
30:31where the carbon ceramic disc brakes are installed.
30:34Our car is so powerful
30:36and the speed is so high
30:38that we need something to break the car
30:40in a very short distance.
30:46The pre-assembly area
30:48in which we are starting from the single components
30:50with the help of this automatic tool,
30:52we assemble all the parts
30:54to create this brake system.
31:00It takes 22 minutes to build
31:02each carbon ceramic brake sub-assembly.
31:10Collectively, they can bring the machine
31:12from 112 km per hour
31:14to a dead stop
31:16in just 43.8 meters.
31:20That's two times the length of a cricket pitch.
31:22The factory is built
31:24on a lean manufacturing principle.
31:26What we are trying to do here
31:28when we were designing the line
31:30is to apply what we call
31:32the lean manufacturing principle.
31:34It sounds modern,
31:36but it's not.
31:38It's a machine
31:40that is designed
31:42to be used
31:44in a factory
31:46and to be used
31:48in a factory
31:50and to be used
31:52in a factory.
31:54It sounds modern,
31:56but it's not.
31:58The idea owes its genesis
32:00to an automotive concept
32:02that's over 100 years old.
32:04We try to design a line
32:06really compact
32:08with all the pre-assembly area
32:10on the side of the line
32:12in a really short distance.
32:14In 1913, Henry Ford
32:16radically changes the automotive world forever
32:18and cuts down the time it takes to build a machine.
32:20But more importantly,
32:22it cuts down on wasted motion
32:24near the line.
32:26By the 1990s, the German auto industry,
32:28including Audi, Lamborghini's
32:30parent company, takes the process
32:32to the next level.
32:34They realize that it's not
32:36just about cutting down the time it takes
32:38to build a machine, but the number of parts
32:40at the factory.
32:42The less parts weight,
32:44the less inventory on hand,
32:46and the fewer mistakes that can be made,
32:48the faster you can build a product.
32:54The result is lean manufacturing.
32:56The pre-assembly is here,
32:58and the assembly point is there.
33:00For the engine, it's the same.
33:02For the dashboard, it's the same.
33:04This is something that we try to apply
33:06in all our production.
33:08While the theory of lean manufacturing isn't new,
33:10Lamborghini's use of it
33:12is rather cutting-edge.
33:14The philosophy is not new,
33:16but it's new in the way in which we are applying,
33:18because we have only men.
33:20We have people which assemble the Lamborghini.
33:22So the challenge for us was to
33:24convert this kind of principle
33:26born for our huge and big
33:28manufacturers to our
33:30craftsmanship activity.
33:32The lean manufacturing philosophy
33:34is an old idea, but it's managed
33:36by a modern technology.
33:38This is a touchscreen.
33:40Every station is at least one,
33:42some stations even two.
33:44The touchscreens keep the factory
33:46constantly updated on the progress of each machine.
33:48If the worker needs
33:50to understand how to assemble something,
33:52he can go inside here, he can go in a server,
33:54and it's written, hold the cycle
33:56plan on the car.
33:58After brake install, they connect the Huracan's
34:00power to the machine's four-wheel drive system.
34:02Four-wheel drive
34:04is now a Lamborghini hallmark.
34:06Once you get to this level of power,
34:08it just becomes easier to put it to all four wheels.
34:10Using a very special
34:12torque converter, the device
34:14controls how much of the engine's power
34:16is sent to the front wheels.
34:18The challenge is
34:20to bring the right power
34:22in the front. We choose
34:24electronic-controlled torque distributor
34:26because in this way we can choose
34:28in real time the exact
34:30amount of torque
34:32we want to have in the front and, of course,
34:34in the rear of the car.
34:36The electronic torque converter senses
34:38traction loss in mere milliseconds.
34:40There are a lot of
34:42ECUs, a lot of power
34:44calculation.
34:46And these ECUs,
34:48these control units, are learning
34:50every time what happens
34:52for driver behavior, and they are
34:54checking also the ground situation,
34:56if there is a slippery, if there is
34:58ice, if there is rain, and so on.
35:00And so, they are
35:02able to react in very few milliseconds.
35:04Under normal driving
35:06conditions, the system diverts
35:0830% of the engine torque to the front
35:10wheels.
35:12However, if the machine
35:14loses traction at the back,
35:1650% of the torque is immediately sent to the front.
35:18If for some reason
35:20one wheel or one axle is
35:22slipping, you can transfer immediately
35:24some torque in the other axle, and to
35:26avoid maybe oversteering
35:28or understeering.
35:30At high speed, the system
35:32alters once again, no longer
35:34sending power forward.
35:36Instead, the Huracán uses all
35:38100% of the torque
35:40at the rear axle.
35:42The power calculation
35:44inside the car is something that is
35:46tremendous. The benefit is
35:48that you can have
35:50continuous changing in
35:52the torque applied to the ground.
35:54Finally, after almost
35:56two days of hand assembly, a new
35:58Lamborghini Huracán is ready
36:00for final inspection.
36:02You see all the lines and all the edges.
36:04We have to respect it to have the maximum precision.
36:06We are talking about less than
36:08a millimeter in order to see that the
36:10line which is starting here is following there
36:12on the front hood without
36:14any disruption. This is our big challenge
36:16when you see all this edgy design
36:18which is fantastic.
36:20It's taken 1,460
36:22days to handcraft that dream.
36:24It's taken
36:26four long years of faith,
36:28a continued desire to
36:30pen radical shapes,
36:32creative engineering solutions
36:34and the means to live
36:36outside of the conventional automotive
36:38landscape. Finally,
36:40Lamborghini's latest creation is ready
36:42to attack the track.
36:50The Lamborghini
36:52Huracán.
36:54The machine takes
36:56its name from a Spanish
36:58fighting bull,
37:00but it traces its lineage
37:02back to a single machine.
37:04The best-selling Italian supercar
37:06ever made, the Lamborghini
37:08Gallardo.
37:10During a 10-year production run,
37:1214,022 Gallardos
37:14are sold. To equal the machine's
37:16success, the Huracán
37:18banks on its Italian heritage.
37:20I think the fact that the Huracán
37:22follows the Gallardo so closely
37:24in its styling tells us that
37:26it was just time for a replacement.
37:28It was clear to the company that this
37:30was a successful business model
37:32and it was a successful product for
37:34the company as a whole.
37:36Today, the Huracán is a 610
37:38horsepower V10
37:40beast.
37:46It's all about the theater.
37:48You flip up
37:50a little cover to hit a start
37:52button, and then the car
37:54starts, and it's loud enough to wake
37:56your neighbors up a block and a half away.
37:58Every single piece of
38:00that car is hexagonal
38:02and it's just
38:04over the top. It's not often anymore
38:06that you get a V10 engine. They're pretty
38:08rare, so it's really
38:10special when you do find one.
38:12The 5.2 liter engine generates
38:14412 foot-pounds of torque.
38:16They've
38:18updated it substantially from
38:20the Gallardo. It makes a ton
38:22of horsepower, and one of the coolest
38:24things they've done is they've made it
38:26sound cool.
38:28That sound is a unique Italian
38:30tune. Part of the
38:32charm and part of the theater
38:34is the noise and the revs.
38:38V10 engines
38:40inherently just generally don't
38:42sound that great, but the Italians
38:44couldn't put out a car that sounded bad
38:46and they've really tuned this one to make
38:48it sound like a race car.
38:53The Huracan not only
38:55sounds like a race car, but it accelerates
38:57like one too.
39:03Going 0 to 100 kilometers
39:05per hour in just 2.5
39:07seconds.
39:09Just three times longer than an
39:11F18 jet fighter to 100
39:13kph.
39:15Launch control is pretty brutal on this car. It actually
39:17physically hurts. It feels like you got
39:19kicked in the chest by a mule.
39:21It will smack you in the back of the head
39:23and launch you down the street before you even knew what happened.
39:25Continue to keep the throttle wide open
39:27and the machine will rocket from 0 to
39:29200 kph in just
39:319.9 seconds.
39:35An eighth the speed of a bullet
39:37fired from a gun.
39:39And the Huracan really
39:41carries on that lineage of making a sports
39:43car. This time
39:45they really got serious about
39:47track performance, about making this
39:49car go around a turn faster
39:51and they've added all this technology to it.
39:53That technology helps
39:55the machine hit a top speed of
39:57325 kph.
40:09It's a car that they've designed
40:11to be more of a sports car and
40:13go out and actually go around corners
40:15quickly and really be fun to drive.
40:19The machine's
40:21ultra-low power-to-weight ratio
40:23of 2.3 kg per
40:25horsepower helps it slice
40:27and dice in the twisties.
40:35The Huracan is so easy
40:37to drive that any novice could go in
40:39and get on the racetrack and not have any problem.
40:43We want to have the driver
40:45in charge and not the car.
40:47What we want is that you are
40:49feeling at home immediately
40:51that it fits like a glove,
40:53that it's not the car dominating you.
40:57That home features
40:59state-of-the-art shock absorbers
41:01that adjust the suspension in fractions
41:03of a second to give the best traction
41:05possible. These special shock
41:07absorbers and these gyroscopes
41:09and all these computer programs
41:11with the goal of making this car
41:13faster around a racetrack
41:15and around a winding road.
41:17The Huracan features
41:19magnetorheological dampers.
41:23The cutting-edge shock absorbers
41:25contain tiny metal particles
41:27in the synthetic oil.
41:29When voltage is applied,
41:31the particles generate a magnetic field
41:33which adaptively changes the amount
41:35of rebound the shock experiences.
41:37The end result
41:39is an infinitely adjustable suspension
41:41system. They really want this to be
41:43a well-rounded supercar that you
41:45really can go out and drive
41:47anywhere and be just as much fun
41:49to drive as any of the competition.
41:51That competition isn't for
41:53everyone. With a base price of
41:55189,000 euros,
41:57the Huracan lives in the
41:59realm of the ultra-exotic.
42:01You're a connoisseur at least
42:03or definitely you're not following the
42:05beaten path there. You're doing something different.
42:09It started with an argument
42:11and a passion for greatness.
42:13A little over 50 years later,
42:15Lamborghini is still chasing
42:17the same dream, to build
42:19exotic, exclusive,
42:21high-performance machines for the
42:23ultra-wealthy. Whether they continue
42:25to succeed comes down to a single
42:27word,
42:29Huracan. Lamborghini
42:31got their recipe right with the Gallardo.
42:33It's relatively comfortable, doesn't really
42:35beat you up, but still gives
42:37you enough sound
42:39and bouncing around enough to know that you're
42:41doing something bad.
42:43It hits the right notes. It's the newest
42:45machine from the house of the raging bull
42:47and now it faces the
42:49ultimate pressure, replacing
42:51the best-selling Italian supercar
42:53ever built.
42:55We have half a century
42:57in our back and for us,
42:59the motto last year was 100 years
43:01of innovation in half the time
43:03and I think this is exactly what we
43:05have to look forward
43:07for the next decades to come.