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Lamborghini Plant Tour

Craftsmanship Meets Modern Technology

SANT'AGATA, Italy — Tucked into this tiny village, not far from Bologna, is a factory that turns out some of the most coveted sports cars in the world. Until recently, Lamborghini produced only about 200 cars a year. Today, in addition to the high-dollar Murciélago, Lamborghini is building a less-costly Gallardo model.

The Gallardo

Even though hand craftsmanship is still king, the Gallardo assembly line—installed during 2003—makes greater use of advanced technology. Electronic machine control performs such tasks as liquid seal application and leakage checks on the V-10 engine. Both the aluminum Gallardo body and its basic engine come from an Audi plant in Neckarsulm, Germany, but all the assembly work takes place in Italy.

Murciélago production is more traditional. The V-12 engine components are machined right at the Sant'Agata plant. Partly because of the power machinery that's needed in engine manufacture, the Lamborghini factory is noisier than, say, Maserati's facility, which does not produce engines.

At Lamborghini, too, the factory floor has a more haphazard atmosphere than most auto plants. Parts along the line are efficiently arranged and shelved according to a Kanban (two-box) system. When one box is empty, a signal warns that new materials are needed. All components have a precise, crafted look when neatly stacked for imminent use. Even so, a strewn-about quality pervades the array of components positioned along the assembly lines.

Engine Creation

Separate engine assembly lines are used for each model. Engine creation "is not the spectacular part of our factory," said Sergio Fontana, Lamborghini's communications manager, "because most people who visit the factory want to see the car, not the parts." Even so, "for technical people," it's a fascinating place.

Boxes of camshafts and crankshafts, and stacks of cylinder heads line the aisles in the Murciélago engine-construction area, which consists mainly of men working at benches. They use both hand and machine process to turn out engine components. A robot is used for machining the valve area of cylinder heads. Power machinery finishes the cylinder bores.

While the Gallardo's compact 10-cylinder engine is assembled at a series of 10 stations, the V-12 line has six stations, with longer cycle times. Most mechanical workers are male, but not all. At one Gallardo station, a man and woman were assembling a cylinder head.

All Parts Equal

Gallardos move along their assembly line at a speed of 6.2 meters per hour, while the cars themselves sit on large stands. As the aluminum body, already painted, arrives at the dedicated line, it faces 22 workstations. Several pre-assembly stations deal with doors, suspension, and other parts. At full capacity, 63 workers build Gallardos.

At the first two stations, the body is lifted and rotated for underbody work. Doors are removed temporarily. At station 1, the front differential and underfloor pipes are installed. Farther down, wiring and internal/external parts are assembled. Power screwdrivers are used for safety-critical parts, such as suspensions.

All specific parts for one car go on a trolley that follows the car through certain stations. The powertrain, with a bench-tested engine, is installed at station 10, using a special crane. After being moved on a trolley to the next area, the powertrain is connected. Wheels go on, seats go in, and doors are remounted. At station 22, the Gallardo is complete and ready for testing.

Murciélago bodies leave the warehouse and join their own 10-station assembly line. The cycle time at each work station is about 3.5 hours. Workers are capable of all operations for that station and for adjacent stations.

Bodies are raised and turned at station 1 so pipes and insulation can be fitted. Most wiring is installed at station 2, followed by engine-compartment components. Bumpers, lights and the hood are added at station 4. Suspensions are next. At station 6, the engine/gearbox/exhaust assembly is mounted—an amazing operation to watch, because the powertrain is so huge. Final steps include fitting of the interior, windows, and doors.

Light Tunnels

Light tunnels, which are an Audi development, are used for checking the quality of body contours on body models. They can help "control the body and paint," Fontana said, which is "not possible with normal light."

Gallardo upholstery comes from outside suppliers. For the Murciélago, leather upholstery is cut, sewn and fastened in the Lamborghini facility, where more female employees are evident.

Italian Style

Near the end of the line, each car goes into a test room, where it's blocked in place. A driver runs it to the equivalent of 220 kph. Both models also will be test-driven on regular roads, for about 100 kilometers.

In the brand-new building that's under construction next door, Lamborghini will have a Customer Service department and a Centro Stili (styling center). "To have a Centro Stili in Italy" is important, Fontana said, "for psychological reasons." Despite ownership by Volkswagen/Audi, "the spirit of Lamborghini has to remain Italian."