This Is How They Make 1 Million Engines Per Year - Come With Me Inside A Super-Modern Engine Factory

[@d4a]

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[@ilovelimpfries]

THis is so cool. Usually, manufacturers will never let you film inside their factories let alone casting foundries.

[@catlee8064]

Now you need to get into the Cosworth factory....have a tour round there.

[@d4a]

That'd be fun! But this was honestly very fun for me from an engineering perspective because the challenges of making a cost-effective engine quickly and in great quantities while also meeting all the new standards and maintaining reliability is arguably greater than making a small number of very expensive, very powerful engines slowly. There's a 50 minute version of this video for channel members and on patreon where I put in all the nerdy details I found interesting.

[@catlee8064]

@@d4a I totally agree with you, the magnitude of this factory is amazing! the logistics and engineering that has gone into it is mind blowing, and i never even heard of Horse before this.

[@Scrizati]

The spray coated cylinders was all new to me, super cool to see how the micro pores hold the oil. I wonder how many mechanics know that new engines don't have cross-hatch

[@d4a]

I thought the same thing...at some point maybe they do the head gasket and think it's all glazed and ruined and convince the customer it's shot 😅 it probably doesn't happen though...I hope

[@vvevvevvvv]

This spray coating has been around for 10+ years already.

[@steven-k7j7v]

It's been around a lot longer than that, Nikasil coating. Moto Guzzi were early adopters plus others.

[@BitterCynical]

@@d4a In Eastern Europe there are a lot of old school mechanics that provide legally questionable service taking cash only without any receipts. If the ones doing engine rebuilds are anything like the ones fixing brakes and suspension and such it's more than likely that there will be a lot of misdiagnosed engine problems. They might decide it's necessary to hone the cylinder walls, maybe even ruin an engine that just needed a new head gasket.

[@ironbuttbill]

Back in the 1980's Mercury Marine was using a hard chrome cylinder coating on their large V6 2-stroke outboards that did not have a crosshatch pattern. It had 'pitting' in the cylinder that was said to hold oil just like what Horse is doing. What a concept to have something like it being used today.

[@HansStrijker]

Okay, I've seen plenty foundries in my life, but never have I seen one this clean! Impressive!

[@ChristopherBurtraw]

Aluminum foundries tend to be much cleaner. My company runs some cast iron foundries (brake discs) that are almost this clean. How we do it is beyond me, makes for great customer tours if they have seen others.

[@grizwoldphantasia5005]

My only comparison is old industrial b/w movies from (guessing) the 1950s or 1960s, and this looks like an electronics clean room or a hospital in comparison, like it was built just yesterday. Really really impressive.

[@AnthonyCarlyle]

haha I want to show my first foundry boss. Why did we not have it that clean?!

[@raymond_rayder]

I'm speechless, man. This is incredible. I'm so happy to see an opportunity like this go to you!

[@WilliamDye-willdye]

8:19 "...no more engine rebuilds"? That statement is worth a follow-up video.

[@AUMINER1]

disposable engines

[@starydwumas7481]

Special cylinder alloy coating, it's more durable and more lightweight but you can't put new coating in basic workshop so it's not possible to rebuild this... Also engines rebuilds are rare nowadays because higher and higher work costs and in most cases not worth it. Like popular engines are easier to pull from crashed car than to rebuild. Also in many engines parts are expensive, like you take good motorcycle engine and it has lightweight rods etc. which are expensive and whole rebuild is veeery expensive and probably not worth it since vehicle bodies crash a lot more often than you need to rebuild engines.

[@AKAtheA]

Ford for example does rebuild plasma coated cylinders (cores from replaced engines), since it's cheap... You can def rebuild this, the one tiny snag is you need a €250k plasma coating machine, so you need a shitload of rebuilds to pay off the machine. btw all those plastic parts will literally fall apart before the cylinders wear out

[@andrewahern3730]

FWIW, taking business and accounting classes have taught me more about why things are the way they are more than anything else could have. In this case, it's worth remembering economies of scale and automation/assembly lines vs hands on craft work. Think of a Bic pen, if it breaks somehow, are you going to take it apart and rebuilt it or toss it and grab another? That's an extreme example but engines are far cheaper than they ever would be due to having a finite life span that is built and optimized for. An engine part that outlives the engine is just an overbuilt part.

[@cookymonstr7918]

It is interesting how different is production today in comparison with couple decades before. No automatic production lines, no conveyers. Flexibility and customization! Such a production facility is able to change its production within hours. Amazing.

[@d4a]

Exactly! Super important takeaway. And they do a bunch of engines here, 1.0, 1.3, 1.2, 1.8, diesel, petrol, three cylinder, four cylinder, hybrid, gearbox cases

[@sandhaug67]

Actually, I was at the Fiat Fire factory in 1989 where they produced the four cylinder 1.0 engine without a human touching them! So it is a little more than a couple decades ago! 😀 And believe it or not; the same year we used AGV's at my working place in Norway!

[@BandaMapper]

Something tells me the guy didn’t get the helium joke 😂

[@d4a]

He probably just wanted to punch me in the face 🤣

[@unklian9221]

WOW! So impressive. Thanks for letting us join you. Sprayed-on liners. Incredible. The stuff of science-fiction.

[@Lumi1975]

infinite engine glitch

[@ottbee6976]

This is so cool! After seeing this, I am realising that we will be driving ICE cars for the rest of my life time.

[@betomanzano]

Excellent video, thanks for the tour. Y gracias al equipo de HORSE por permitir esta interesante visita virtual, saludos desde México 🤠

[@Tangloppen]

Fantastic tour and video. The level of automation is incredible, I thought it would be more “hands on”.

[@fritzbrause6332]

Wow! Amazing video and so much information in such a short time. Massive thank you for making and publishing it! What an emotional moment such a first start of an engine actually is :-) Wonderful

[@72plyduster1]

I worked for nagel it’s a honing company in Germany, also have a plant in US. They made honing equipment to put the crosshatch pattern in the cylinder bores, and the correct diameter of bores.

[@exeteral1031]

Amazing video! It’s very interesting to see how much technology and machinery is involved in making an engine. it feels like I’m seeing the factory in person! 👍

[@placacentrocasamania]

Each video, something new to learn Saludos Gerardo

[@jozsefizsak]

That was astonishing! Thank you once again. 😊

[@heidymadia3065]

Horse: No engine rebuild [Sad tuner noises]😅

[@gordonborsboom7460]

May not be true in an absolute sense. I'm sure someone can cut out the liners and insert new conventional steel liners. It is probably more expensive than a new block

[@TML34]

@@gordonborsboom7460the problem is the cylinder walls are made to a minimum thickness. Not like the old cast iron blocks. 😅

[@gordonborsboom7460]

@TML34 I'm sure you are right. Only the minimum material necessary is the best engineering and cost objective.

[@charkuat]

Amazing, well done, super coverage of a modern A to Z manufacturing facility.

[@daniellore2961]

This was fantastic! Thank you and we'll done.

[@AUMINER1]

That was an incredible tour of the inner workings of a modern factory - the years it must have took to build that factory and tune it to perfection is truly impressive! one million engines!

[@TomahawkTX]

This is so valuable. Thank you!

[@TracyNorrell]

I love so much about this video. It has real "kid in a candy store" vibes.

[@balazsjozsa4301]

Amaizing content, thanks for sharing!

[@PeterR0035]

Impressive video ❤ Glad you got to experience the manufacturing process!

[@a-dp6bq]

This is gold content. Always a pleasure to watch your videos!

[@alanpayn8699]

Excellent video!!

[@bonovoxel7527]

Josef Prusa likes this!!

[@d4a]

3d printers assemble!

[@johnpenwell6402]

Awesome video, really cool to see the whole modern manufacturing process from block casting to dyno testing. If you ever get a chance to film another engine, transmission, or whatever factory id say do it because this was really neat to watch.

[@Kevin-ti3rz]

Congratulations on your VIP Tour of the Factory . I had one with my Hockey team in the 80s at the Ford Factory. Really amazing automated machines they had back then. Now it is mostly if not all .

[@JVonk]

Really cool content! And a big thumbs up for Horse, I would have never guessed they would allow this.

[@grizwoldphantasia5005]

They have to be proud of their work to allow a tour like this.

[@sayeedalsifat1308]

14:03 london bridge plug

[@CedroCron]

Thanks for the great video, while I will never drive on one of these engines here in Canada, it was neat to see some of the cutting edge technologies like the spray on piston liners. I had heard about it but never saw it applied. Really cool.

[@tacticlol]

Honestly you can’t say for sure you’ll never drive one. My Chevy Equinox has an engine that was designed in Italy/France and IIRC made in Hungary.

[@CedroCron]

@@tacticlol No I'm sure...

[@po1nt1776]

We need more factory sneak peeks! Great video! I have like a million questions about the process and I could annoy them for the whole day. Can I come with you next time?

[@warrenlucier5796]

Thanks for the engine plant tour. One usually doesn't get to see the procedures being done on the really important aspects, Like the ability to see if the are imperfections with wall thickness and core shifts. I also liked where they had cut the cylinders to show the differences in the liner types and why the plasma arc iron spray bore is used. They can be repaired also. You might want to look into the laser welding Alusil cases and heads vs having to replace them.

[@RusselLee]

Wow how fun was that! The cylinder treatment blew my mind. Would really like to know more about it. Things like how long does it last, what is the friction difference, any increase/decrease in power out put, and what is the heat expansion like between the materials.

[@d4a]

Friction is reduced, block weight reduced by 1.1kg and emissions are allegedly improved too. I wasn't given the exact numbers unfortunately but they probably have a study on it somewhere.

[@RudaBL]

Bravo KRALJU 🙂 Prešao si na viši nivo i svaka ti čast što nam donosiš ovakav sadržaj na youtube. Bilo je uživanje gledati ovaj, a i svaki tvoj video! Hvala ti na svemu i pozdrav iz Banja Luke ;-)

[@colincampbell4261]

Looking forward to watching this right now, thanks.

[@TheRealWindlePoons]

Interesting video, thank-you. I am a retired control systems engineer. I have worked in several engine plants 20-35 years ago (Ford and Nissan in the UK). It is interesting to see how things have progressed. Good to see the Automated Guided Vehicles. I once worked in a food factory where one had been "kidnapped". Someone had added side-skirts, chin spoiler and rear spoiler in cardboard and added a poster down the side saying "Pimp my AGV". 😀

[@WiwatChang]

Thank you so much for this video as I've learned something new eventhough I've visited several car assembly plants in 5 different countries but never in the engine manufacturing section. Except the Porsche engine hand assembly station but that's more a like handicraft rather than automation like most.

[@just.jose.youtube]

Great tour, thanks! 🙏

[@gordythecreator]

Another great idea from my favorite Italian. I'd love to work there everyday. A challenge worthy of my capacity. I'll have the entire plant memorized within one year

[@msdvahedi]

fascinating, so much thought and engineering

[@RandomPasserby-l5x]

3:15 Prusa3D printers detected. 😆 Regards from Czech Republic.

[@SquiddyyBoyy]

He said 3d printers and I was expecting a 7 figure beast but lo and behold, a prusa

[@timessix8434]

Also the combustion engine part of Volvo Cars is now part of Horse, making several hundred thousand engines in Skövde, Sweden, on top of R&D in Gothenburg.

[@vladdutz20]

Glad to see you invited there...see you soon on the shore of the Atlantic Ocean:))

[@_RAQUERO_]

Being in Valladolid you should had try ro contact Michelin, Faurecia and ZF to visit their factories and R&D offices

[@francisconunes173]

Great experience! Cheers!

[@gerry343]

Designing the factory is an incredible achievement to start with.

[@Kapil-Patel]

This was insane, thank you for sharing bro 👍🏽

[@luizhcgoncalves]

**Ugga Dugga sounds** got me good there

[@michaelrockwell9691]

That place is awesome!

[@TestTest-eb8jr]

Great video 👍👍👍

[@usd25674]

Very interesting. Thanks for your great work as always.

[@d71mau]

Looks like you had a wonderful day, I'm glad you enjoyed it.

[@AnyoneSeenMikeHunt]

Surprised this factory is in Spain not China.

[@JSmith19858]

China is too expensive now. A lot of their manufacturing has moved elsewhere in Asia, like Vietnam or the Philippines

[@_RAQUERO_]

@@JSmith19858 that has nothing to do with this factory, this factory open in 1953 to manufacture cars, the engine factory came some years later

[@AnyoneSeenMikeHunt]

@@JSmith19858 Good.

[@JSmith19858]

@ yeah, I mean, it's not like the factory could be closed and production carried out in China. It was a car factory since 1953, so by law it has to stay open

[@AnyoneSeenMikeHunt]

@@JSmith19858 By law? Wha?

[@robinguitar]

Amazing factory.

[@feenyx6394]

That's incredibly cool!

[@dave_rv_there_yet1728]

Thank you again for another awesome video… you are at the top of your game on the net… your explanations and insights “dumbed” down so all levels of intellects can understand is awesome… thank you for doing what you do…

[@mackalack1019]

This is awesome!

[@Automan9]

What a treat ! Also you're so silly 😂

[@airwaynelson]

great video!

[@gregcharest443]

Really impressive!

[@ilkkasorsa9778]

As a blind person, I am intrigued in the history of their name. It's always good to stay true to your roots, though, regardless of drastic changes in the business model.

[@jpwillm5252]

Très intéressant reportage ! Les images et le son sont parfaits. ** Very interesting report! The images and sound are perfect.

[@bowieinc]

Great video:).

[@Engiction]

What is this two of my most favorite content engineering and manufacturing 😂

[@stevekent5368]

Thank you very much

[@Ur3o]

Approximately 1,9 engines per minute :) good job 👍

[@hojbota-ptv]

this was impressive

[@jeffrandolf5673]

20:11 "Ugga Dugga sound" 🤣😁🤣😂

[@andersemanuel]

So cool! Contrasts to being a mayor player when someone wants to show off their interesting stuff.

[@steveenghsr2100]

Thanks

[@sapte62]

I have one of those engines, a 3 cylinder 1.0tce fitted to a Dacia Sandero. No problems so far (40k km), luckily for me I do not intend to keep the car long enough to need an engine rebuild. Consumer age...

[@vvevvevvvv]

It's an ok motor. They even come with LPG injection as standard. Economical and cheap to run.

[@d4a]

Yes, they do the 1.0 in this factory too, but most of what you have seen is the new 1.2 (HR12) that will go into hybrid drivetrains.

[@sapte62]

Yeah, mine is one of those. Got an extra 10 hp ​and some NM when running on LPG. Did not knew about the micropores, seems that the method works well since I do not experience any oil consumption.

[@TML34]

Good news!!

[@jalalvafa8979]

Thank you

[@TML34]

I don’t know why, but I love the robots that apply the sealant. That’s peak-progress to me! 😂

[@norbertdapunt5092]

Awesome.

[@faraztabatabaie2255]

Champhering is fun!!! I like Champhering 😂😂😂 I've never related to someone so much!!!

[@DABrock-author]

To quote Blondihacks, “Chamfers are what separate us from the animals.” 😂

[@johnridley1038]

What an amazing visit, Coupled with this is the 30Mw of power needed to produce the engine. thats about 10% of a nuclear power station.

[@neilgarrad4931]

Thanks.

[@BitterCynical]

I guess the cylinder steel coating instead of a sleeve insert makes the block cheaper to make. Probably can't machine it to a larger bore when it's worn out, unless the coating has considerable excess thickness. The temptation is to say it's worse for ecology but I wonder what percentage of worn engines get rebuilt anyway. If most of them end up melted down to be used as raw metal again then there's no point going through the effort to make engine blocks that can be reused multiple times.

[@d4a]

From what I gathered this is more expensive, the technology and machine itself is incredibly expensive and it only makes sense with massive engine quantities. The only reason they do it I think is efficiency, emissions and weight reduction. When it comes to rebuilds, I'm afraid you're right, the only engines that get rebuilt in most of western Europe nowadays are special, valuable or large industrial and truck engines. The price of a rebuild usually doesn't justify it for a small car engine.

[@BitterCynical]

@@d4a Oh that's ironic, so it makes for a more efficient engine with better emissions but no more reusing of a worn out block. Cuts out one of the parts in Reduce, Reuse, Recycle to focus on another.

[@Torchedini]

@@BitterCynical Emissions is not a option though. You meet and sell engines or do not meet and do not sell engines. As such technologies like this make sense. Also for the manuafacturerer at some point the cost of an engine replacement is lower than an engine rebuild. Especially in western europe where labour by a mechanic at a dealer is way more expensive. So the reuse in the later part of the process is not interesting. Secondly, manufacturer makes more money on selling new things than providing warranty on old things. It is all economics, which is why emissions are written in law because manufacturer and end user do not care at the point of sale. (in case of these small engines anyway)

[@filippivonka5181]

19:05 we still have timing marks thank God 😂

[@d4a]

I've seen some new engines that have nothing. You have to buy a prohibitively expensive special tool to time them.

[@filippivonka5181]

​@@d4adamn, that sucks.

[@TML34]

@@d4ago by ear. oops, we bent that valve, guess I was off a couple of teeth. 😂

[@Novus_Ordo_Conditor]

7:14 As far as I'm concerned, this technology is nothing more than Renault's quest for more profit by producing completely disposable engines! What was wrong with the piston liner? But here it's all about defrauding the customer. The excuse of the pressure of the euro6 standard is just a cover. But on the positive side, the thing that I appreciate most about the company is that they shared without restrictions, they explained all the details one by one and went forward, that's definitely something to be respected.

[@Poult100]

I would love to know the life expectancy of the sintered cylinder bore, compared to a traditional pressed sleeve! Amazing processes!

[@psircos]

I wonder if this video will do the best for you, coz for us geeks that was brilliant 👍

[@d4a]

Made for geeks by a geek! I don't care how the video does, I want to share with the people that will appreciate it and maybe learn something from it.

[@psircos]

@d4a I have the AR gta in bits at present. Not completely, but everything was off apart from the head and TB assembly. I have dismantled, rubbed, repaired, sprayed, yadda yadda yadda, and I wouldn't have anywhere near the knowledge/understanding of what I was looking at, if it were not for Italian Autos, yourself and similar channels to help me cope! It's always appreciated 👏

[@Asmiiirr]

Cool experience, thanks for taking us with you 😊 One of these engines is in my 2024 Peugeot 3008 right now.

[@TML34]

Does it burn oil? 😅

[@Asmiiirr]

@TML34 nope, done 26.000km not a single issue

[@nigel660]

I thnk the next vidoe on this channel needs to detail all the cylinder preparations with their limitations/ advantages. Maybe we can then prevent an uninformed machanic causing more damage to our engines.

[@darkally1235]

I wonder what advantages bore spray coating has over the traditional steel sleeve. As you pointed out, there's no sleeve which can be replaced if it's worn or damaged, so hopefully it will last as long as a typical engine. And it seems like quite a lot of expensive technology - so there has to be a cost savings or another significant reason somewhere. Maybe it decreases emissions enough to justify it?

[@manuellongo4365]

It seems amazingly quiet in there - is it ?

[@d4a]

It is very loud, especially at the foundry and in machining, hence the headphones.. I used mics that cancel background noise and spent hours on audio post-processing just to get to this barely passable level of quality. It's an audio recording nightmare tbh.

[@junit483]

Spray welding with high porosity and 500 bar tensile strength.

[@barrattiel911]

Great video, it was very interesting for me to watch how engines are produced, I only have one remark, when there are other people talking, it's appropriate to introduce them so we know their names, it's very unpleasant to listen to someone talking and not know anything about them... anyway, great work, keep entertaining us :)

[@progkarma944]

Great video!... Question - With the change to the cylinders, you mentioned "no more rebuilds" can you elaborate on that?

[@TheBlibo]

Interesting Not seen metal spraying g of cylinders before but quite obvious really ( seen old cranks sprayed to give them a new life with good results ) metal spraying for cylinders is also cheaper than nicosil or similar ceramic coating, It also make the engine a one time use which is not particularly green. Still great vid as usual

[@Mr2ronron]

Really neat to see but where are the crank, conn rods, gears, turbos, and pistons made?

[@azrobbins01]

A million engines per year? One engine every 30 seconds? I am amazed they can sell that many, and I had never heard of them.

[@Kevin-ti3rz]

Kawasaki did a spray in liner in the 80s . I think they had issues . The KX 125 I had could not be bored out because it had a Teflon type of liner

[@d4a]

I think nothing with any sort of extra layer can be bored out? Even more conventional electrodeposited stuff like nikasil can't be bored out if you don't have the means to re-plate it again? Unless it's deposited super thick which I believe it rarely is?

[@secondmouse9458]

Did you get to keep the jacket? Where does the HORSE name come from? An acronym? Great video, love seeing how things are made, thanks for sharing!!

[@d4a]

I asked about the name too, unofficial answer is that Renault made the Horse division for ICE and the Ampere division for EVs. I didn't keep the jacket, but I got a lot of other cool Horse branded stuff 😁

[@ঘ্যারত্যারা-ন৭য]

Owo nice❤