Mack Trucks' Macungie Assembly Plant

Upon entering the lobby of the Macungie factory, visitors are greeted by a display case full of interesting Mack knick knacks: toy models of many Mack models; two commenorative plates; a 2008 'Climate Leader' award from the Environmental Protection Agency; the key to the city of Allentown, Pa.; and several sculptures of Mack's ubiquitous logo -- the Bulldog.

John Walsh, Mack's vice president of marketing, checks email while waiting in the other half of the Macungie facotry lobby.

A piece of steel from the World Trade Center is the centerpiece of a September 11 memorial wall -- steel presented by the New York Fired Department to Mack Trucks as a token of appreciation for the company's support efforts during the clean up at ground zero.

Paintings made by artist Charles Vlasics adorn the hallway leading to the entrance of the Macungie factory floor.

The Mack store right beside the opeing to the factory floor offers a variety of items for sale -- T-shirts, jackets, hats, you name it.

Hanging from the ceiling of Macungie's Mack store is a toy train emblazoned with the company logo -- a little ironic since the plant produces trucks, not locomotives.

A super-large version of the Bulldog statue affixed to the hood of every Mack truck stands guard at the factory floor doorway.

Right inside the main doorway into the Macungie plant is the cab line; producing a wide array of cabs to fit the 12 models of trucks built at the factory.

Close beside the cab line is where the sleeper bearths are built and attached to the cabs.

Cabs for Mack's TerraPro cabover vehicles -- many earmarked for refuse service -- are built in an area separate from the conventional cabs.

Special 'carts' can be constructed -- or reconstructed -- to hold any all types of components for the production line.

Recycling is a big deal at the Macungie plant -- literally. In 2011, the factory recycled 440 tons of cardboard (more than 36 tons per week) and 200 tons or scrap metal (some 16.5 tons per week) as well as 54 tons of paper and 25 tons of clear plastics.

The paint booths switched from being powered by oil-fired boilers to natural gas to reduce emissions and save on energy costs. In fact, the Macungie plant reduced its energy consumption 48% between 2004 and 2009 alone.

"Paw prints" mark parts of the production line; a testament to Mack's "Bulldog" logo. British soldiers bequeathed this unique moniker back in 1917 after using the AC model as troop transporters during WWI, dubbing them 'bull dog models' due to the shape of the truck's nose and front grill.

The "groom line" is when transmissions, fan blades, EGR piping and other final components are added to the truck engines.

Transmissions are tagged and parked to wait patiently for the moment when they get added to the "groom line."

Special 'one way' screws are used to prevent anyone from removing the bulldog statuette adoring the hoods of Mack truck models. Incidentally, legendary Mack chief engineer Alfred Masury designed the very first 'bulldog' hood ornament while recovering from an operation in the hospital back in 1932 -- reportedly carving it from a bar of soap -- as a way to keep his mind and hands occupied while laid up.

Attaching a hood on the Macungie production line.

Tires are mounted on hub assemblies in a different part of the plant, then delviered to the production line via conveyor belt.

If you get hungry on the assembly line at Macungie, there's no need to go in search of snacks -- the snack bar instead comes to you, loaded with everything you could ask for on a motorized cart.

All fluids and a little diesel are added to the trucks being constructed at Macungie, so they are literally "driven off" the line once completely built.

A final battery of tests -- including the alignmnet check pictured here -- are conducted on all newly produced models at Macungie once they leave the line to ensure they're ready for delivery to the customer.