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In a process described by Briones as a "marriage," the Bora's chassis comes up from below, in a single step. Sensors at front and rear guide the mating, and tolerances are claimed to be about 0.1 millimeter. For other models, the body/chassis joining takes place in a series of several steps. Doors are reattached later in the process, after interior elements have been installed. White paper is applied to the nearly-completed car for protection; it will be taken off later, at the dealership. Near the end of the line, a computer is placed on the steering wheel, to check all electrical components. Wheels are attached, and each car gets 12 liters of fuel (gas or diesel). Four-fifths of the wheels come from the U.S., but 20 percent are made in Mexico. All told, it takes 30 hours to assemble a typical Volkswagen at Puebla. Every car is tested on the 3.5-kilometer track, which contains several pavement surfaces and curves as well as straightaways. The track is used 24 hours a day.
Volkswagens also get a seven-minute water test, to find any leaks. About 80 percent of the Volkswagens built in Puebla are exported - half of them to the U.S. Some cars are shipped to Veracruz or Acapulco, where they will be loaded onto ships. Others go north by train, for a 60-hour trip to Houston or San Diego. Ships hold 6,500 cars. Like a small city in itself, the Puebla plant has its own fire station, along with a medical center, five banks, and a travel agency. Three lakes may be seen on the premises, supplying recycled water for the fire station. More than a hundred buses provide free rides to workers who live in the Puebla area. Volkswagen even boasts the biggest restaurant in Latin America: eight separate units; preparing and serving some 14,000 meals each day. Not far from the plant entrance is a Beetle monument, commemorating the importance of that model to Volkswagen's history and development. Nearby is the "Memories of Tears" Hall. Some 3,000 units of the last edition were produced. In October 2007, Volkswagen celebrated the 10th anniversary of the New Beetle. To mark the 10th anniversary, a Barbie special-edition has been introduced. Another special edition, said to be "for boys," also is expected to emerge. Attention Editors: The full Volkswagen factory report, based on a tour conducted in a roofless VW Komti, is available for your publication. Flammang; interior factory photos supplied by Volkswagen de Mexico.
