The assembly line

This is the first step on the assembly line, when the doors are removed from the bodies in order to work on them separately on the door line. If the doors were to remain on the vehicle, many of the subsequent interior line assembly steps could not be performed. Following this step, the cockpit, one of the largest complete modules, is installed in the Macan and Panamera. Depending on version and fitting, a cockpit may consist of up to 200 individual parts, weigh between 50 and 90 kilos and have a combined cable length of about 3 kilometers. Our colleagues on the assembly line perform this precision work using a handling device which is docked to the cockpit and allows them to guide the cockpit into the vehicle.

Other components assembled in this step include sliding or panorama roofs, control units and the rooflining, including grab handles and sun shades. The final step on the interior line is training the key, which is put into the ignition here for the first time.

Here we complete the assembly of the underbody of both models, including brake and fuel lines and all kinds of cable harnesses. Fuel tank and park heating are also fitted into place here.

On the exterior line, robots fit the front and back windows and bond them into place. In addition, the Porsche crest is placed on the Macan and Panamera models. At the end of the exterior line the completed doors are once again fitted onto the body. Once they have passed this last part of the pre-assembly, the vehicles are conveyed to the mix line for final assembly.

In this area, gear transmissions and components such as a/c compressors, generators, starters and servo-pumps are attached to the engines delivered. The engines are then subjected to meticulous quality control. If they pass, they are taken to the “engagement”. Engagement here means that the completed engine-transmission unit is placed onto the front axle of the vehicle.

Following work on the exhaust system, axles and steering, the vehicle is ready for “marriage”, one of the most spectacular steps on any vehicle assembly line. Here, an automated guided vehicle system (AGVS) places the completed drivetrain underneath the associated vehicle body and bolts it firmly into place. In this way, the engine, chassis and body are virtually “married”. In a final step the tailpipes are installed.

All systems are connected here to get the vehicle ready for subsequent filling. Among the systems connected in this step are the brake lines on the front and rear axles, the fuel pipes and the air line components for the pneumatic springs. The rear lettering is also fitted at this station.

Fuel, coolant and brake fluid are filled into the vehicle swiftly and accurately using a state-of-the-art vacuum/pressure filling system.

Prior to installing the wheels, the steering wheel and driver airbag are installed. Subsequently, the wheels are mounted using a handling unit and a bolter. Each wheel weighs 35 kilos and is fastened with 5 bolts.

In the test bay, the vehicle is placed on its wheels for the first time. After the programming of various control devices comes another exciting moment: the engine is started for the first time. Further steps include some final chassis and headlight tuning and the calibration of the driver assistance systems. The wheel alignment is measured with tracking cameras and adjusted manually. A steering wheel balance guarantees the straight-ahead position of the steering wheel. On completion of these steps, the vehicles are then taken to the chassis dynamometer for a driving simulation at a maximum speed of 120 km/h for a total distance of 1.5 kilometers.

As every Porsche has to meet the highest quality standards we subject each vehicle to a very thorough inspection before delivery. During this final quality inspection, experienced colleagues test the vehicles on our own test track. They test the lights in a darkroom and water tightness using a sprinkler system. After that, each Porsche is taken to the wash box and the interior is cleaned. Having passed further quality check-ups the vehicle is finally released and packed for transport.

During the audit, individual vehicles of each model line are subjected to an even more thorough inspection, including functionality, lighting and road tests. The audit also focusses on aspects such as surface finish, paint finish and seams.