Ep 1. Volkswagen Mega Factory

Richard Hammond's Big is a fascinating documentary series that takes viewers on a journey to explore some of the world's most impressive factories, featuring state-of-the-art technology, ingenious design and incredible engineering.

In the first episode of season one, titled "Volkswagen Mega Factory," Richard Hammond takes us to one of the world's largest car factories in Wolfsburg, Germany, where he gets an extraordinary behind-the-scenes look at how Volkswagen builds its iconic Golf hatchback.

Hammond starts his tour by taking us on a ride through the vast Wolfsburg factory complex, which covers an area the size of Monaco. He reveals that the Volkswagen factory has an incredibly efficient production line, capable of manufacturing over 3,800 cars per day. The factory employs over 50,000 people, with over 1,500 robots working alongside them in perfect harmony.

We see Hammond explore the various stages of the production line, from welding and painting to assembly and testing. Every step of the process is meticulously planned and precisely executed, with each car taking just 32 hours to complete before it rolls off the production line and onto the streets.

The attention to detail and quality control at Volkswagen is truly impressive, with every car undergoing up to 29 hours of tests and checks before it leaves the factory. We see how every car goes through a series of rigorous performance tests, including being driven for hours in a vibration simulator and sent through a water tunnel to ensure there are no leaks.

Throughout the episode, Hammond shares fascinating facts and figures about Volkswagen's production process, such as how they use 8,000 liters of paint each day and how they recycle over 90% of the materials used in production to be reused in future cars.

We also get to meet some of the people behind the production process, including the dedicated engineers and designers who spend years perfecting each and every detail of the Golf. Hammond talks to one of the designers who shows him the computer-aided design software used to create the car's sleek, aerodynamic shape, and another engineer who demonstrates the complex suspension system that gives the Golf its smooth ride.

Overall, "Volkswagen Mega Factory" is a captivating and informative episode that provides an in-depth look at one of the world's most impressive car factories. Richard Hammond is an engaging and knowledgeable host, whose passion for engineering and design shines through in every scene. Whether you're a car enthusiast or simply curious about the manufacturing process, this episode is sure to leave you impressed and inspired.