A factory fit for a king's car

Floors pristine enough to dine on, lights so bright they dazzle, gleaming white paintwork and people dressed in green

Floors pristine enough to dine on, lights so bright they dazzle, gleaming white paintwork and people dressed in green. But this isn't a scene from a hospital theatre. This is where one of the world's most prestigious and luxurious cars are built - the Bentley Motor Company.

It's here in this clinically clean environment that Bentley's two models are built here - the luxurious Arnage and sporty Continental GT. But the versions which leave the plant are numerous as Arnage models are built to a wide variety of specifications. It's a case of anything you want, we can do.

There's the one fitted with a 24-inch plasma TV screen in the rear for an electronics whizzkid in China, one to celebrate Queen Elizabeth's Golden Jubilee with height adjustable rear seats so that nobody is sitting taller than herself, and one for the Beckhams with a leather child-seat embossed with Brooklyn's name, and a special compartment for Victoria's make-up.

All these cars spend time being adapted in the Mulliner coachbuilding area - a factory within a factory on this 68-acre site at Crewe in the north-west of England.

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Over half of Arnage models built pass through the Mulliner workshops, but the Continental GT doesn't offer the same degree of options. Both models are built in the same factory on parallel running assembly lines which move at the rate of six inches every minute.

On the Continental GT line there are five people to every car with 120 cars at a time on the creeping assembly line. More people work on the Arnage which is the bespoke, hand-built car and takes 450 hours to complete.

It's much less for the Continental - just 150 hours - but still seven times more than an an average hatchback. The last time I was here was almost six years ago for the launch of the Rolls-Royce Seraph. Then I thought the establishment was very laid-back and quaint, but everybody still had a pride in their work.

Since then things have moved along, with the sale of of Rolls to BMW and its subsequent move to a manufacturing plant in the south of England, while Bentley stayed put and has benefited from massive investment by new owners VW.

But one thing doesn't alter - everybody is still proud to work here and now even more so.

"This is a better environment to work in than in the past - we now have a good car scheme and the pay's not bad either," laughs Dave Perry, who is a woodwork associate. All employees - now numbering over 3,000 - are called associates. His job has been transformed by the arrival of new laser cutting equipment which ensures that the real wood veneer is accurately cut to a slender depth of 0.6 mms.

Woods used for the different veneers - including redwood and English oak - come from all over the world with the popular walnut from California. It takes nine days to process the wood for the GT - 13 for the Arnage.

Leather, too, plays an important part in a Bentley interior and the same care and attention to quality is given to choosing the perfect hides. Cow hides are selected from Scandinavia where there is no barbed wire or fly disease to damage the fabric.

Each Continental uses 12 hides - one extra for the Arnage - and they are closely examined by laser machines as well as the human eye to detect the slightest blemish. The fabric is precision cut and passed on to a team of 39 seamstresses who deftly stitch the seat covers. The same care is applied to building the steering wheel complete with its leather cover, and takes three-and-a-half hours to finish.

Customers are welcome to visit the factory, which operates a two-shift, four-day working week, to see the work progress on their pride and joy. But before they can take possession of the highly polished gleaming machine, it gets a 40-mile road test carried out by two technicians as well as a detailed check on the company's 500 metre test track which replicates seven different road conditions. And one in 10 of the cars are picked at random to go through an audit station, where lights as bright as sunlight pick up the minutest imperfection.

But anyone who has ever visited a mass production car plant will immediately notice one thing missing - robots. Just two are used here - the rest is down to man or woman.

Bentley, which was started in 1919 by aero engineer WO Bentley, was bought by the Volkswagen Group in 1998. Already £217 (about€325) million has been invested in the production of the Continental GT, of which £154 (about €230) million has been spent on supplier tooling, and the remainder on buildings, including the new assembly line. "There is no other factory like this around the world today," says regional marketing communications director Andy Watt proudly. "We want to be the envy of our competitors." I'm sure they are.

Facts and figures:

Bodies for the Continental GT come already painted from a new plant in Germany.

The W12 engine block for the GT comes from Germany, but the engine is built to Bentley specifications in the engine workshop at Crewe.

Bentley has recruited over 1,000 new employees over the last three years. Most are engineers and manufacturing employees for the GT programme.

The name of the engine tester is shown on a plaque on the engine of the Arnage.

3,500 Continental GTs are being built annually, but Bentley hopes to see the figure increase.

Bentley customers are 96 per cent male, aged about 53 and are self-made businessmen.

The Continental is expected to attract a younger audience of around 40 years old, and a greater proportion of women.

Worldwide, there are 127 Bentley dealerships with 33 across Europe.

America is the biggest market for Bentley, with Britain the next.

Markets opening up include South Korea, South America, Taiwan and Russia.

Between 25 to 30 cars a year are sold in India, and China's five dealerships sold 64 Arnage last year.

There are 7.1 million millionaires in the world today, providing a ready market for Bentley's luxurious limos.