US20080086976A1

US20080086976A1 - Housing manufacturing system and method

Info

Publication number: US20080086976A1
Application number: US11/675,938
Authority: US
Inventors: Peter Gilgan
Original assignee: Mattamy Corp
Current assignee: Mattamy Corp
Priority date: 2006-10-11
Filing date: 2007-02-16
Publication date: 2008-04-17
Also published as: CA2563187A1

Abstract

A system for manufacturing homes is provided. An embodiment includes a sub-assembly plant for assembling planar sections of a home according to production schedule for custom homes. The embodiment also includes at least one final assembly facility located proximal to a subdivision where a plurality of the custom homes are to be situated. The final assembly facility is for receiving the planar sections from the sub-assembly plant and for constructing the homes from planar portions according to the production schedule.

Description

CROSS-REFERENCE TO RELATED APPLICATION

Applicants claim priority of Canadian Application, Ser. No. 2,563,187, filed Oct. 11, 2006.

FIELD OF THE INVENTION

The present invention relates generally to construction and in particular a housing manufacturing system and method.

BACKGROUND OF THE INVENTION

Housing is a critical aspect of social living. The construction of houses and other dwellings is therefore a well-known and highly refined art. Construction techniques and esthetic styles are well known for single family dwellings, detached and semi-detached houses, condominiums, apartment buildings, town houses, and the like.
Automation is also broad reaching and used heavily in a broad range of industries and is used to build cars, trucks, planes, electronics, appliances and many other products. Automation techniques are increasingly being applied to the housing industry, and indeed are used heavily in the manufacture of modular and panelized homes. Modular and panelized homes are well suited to automation due the fact that each unit is substantially identical and therefore an automated assembly facility can be designed to build each unit in substantially the same way using substantially the same components for each unit.
Far more vexing, however, has been the application of automation techniques to conventionally site-built homes. Conventionally site-built homes are typically built on the final construction site. They are often favoured over modular and panelized homes as they can be uniquely designed, both on the exterior and interior, to reflect the individual tastes of the homeowner. Many agree that a community of conventionally site-built homes is also far more aesthetically pleasing than a monotonous matrix of identical modular or panelized homes.
The uniqueness and size of each conventionally site-built homes is anathema to prior art automation techniques. The uniqueness of each home makes it difficult to manage and store stock. The size of each home makes it difficult to transport the home from the manufacturing facility to the site of the dwelling.
The prior art reveals several attempts to automate the construction of conventionally site-built homes. In 1978, U.S. Pat. No. 4,110,952 to Blachura, proposed a technique for constructing individual houses in a factory and delivering them to prepared foundations on a large tract of land. The issue of size was addressed by locating the factory near the final tract of land where the house would be situated, thereby minimizing the traveling distance from the factory to the final site of the dwelling. More recently, U.S. Pat. No. 6,253,504 to Cohen et al. proposed a movable manufacturing facility The movable manufacturing facility of Cohen intended bring standard size home building comprehensively within a controlled factory environment. Cohen disclosed that the main structure of the movable manufacturing facility was sufficiently tall to allow assembly and movement of standard size homes within. Cohen proposed multiple independent production lines to each produce portions of the dwelling in the form of subassemblies.
Unfortunately, the prior art has not proposed a practically feasible automation method for conventionally site-built homes. Since the facilities must be located close to the site for each house, the prior art facilities cannot produce enough homes to justify the capital investment required for the associated facility.

SUMMARY OF THE INVENTION

In an aspect of the invention a system for manufacturing homes is provided. The system includes a sub-assembly plant for assembling planar sections of a home, such as walls or floors, according to production schedule for custom homes. The system also includes at least one final assembly facility located proximal to a subdivision where a plurality of the custom homes are to be situated. The final assembly facility is for receiving the planar sections from the sub-assembly plant and for constructing the homes from planar portions according to the production schedule. Each home in the production schedule can be different.
The sub-assembly plant of the system can include an assembly line for producing at least a portion of the planar sections.
The sub-assembly plant of the system can include at least one of a framing station, a drywall application station, a mechanical services station, an insulation station and a covering station. The insulation station can comprise an injector and a flowable closed cell foam dispenser for injecting the foam into a cavity defined by a frame and a drywall covering of the frame.
The planar sections can comprise wall sections that are provided with a plurality of removable hangers.
The system can include a truck for transporting the wall sections includes an overhead rail for receiving the hangers. The truck can include a plurality of floor rails, one floor rail corresponding to each overhead rail. The floor rails are complementary to a skate, and a plurality of skates can be used to move each wall section.
The final assembly facility of the system can include at least one area for building a roof for each the home and an overhead crane for placing the roof on a respective home according to the production schedule.
Another aspect of the invention provides a truck for transporting planar sections of houses including a plurality of substantially parallel overhead rails for receiving hangers disposed within the sections.
The truck can include a plurality of floor rails, with one floor rail corresponding to each overhead rail. The floor rails of the truck are complementary to skates, and a plurality of skates can be used to move each planar section.
Another aspect of the invention provides a sub-assembly plant for assembling planar sections of a home according to a production schedule for custom homes, the sub-assembly plant for providing the planar sections to at least one final assembly facility located proximal to a subdivision where a plurality of the custom homes are to be situated. The facility is for receiving the planar sections from the sub-assembly plant and for constructing the homes from the planar sections according to the production schedule. The sub-assembly plant comprises an assembly line for producing at least a portion of the planar sections.
The sub-assembly plant can further comprise at least one of a framing station, a drywall application station, a mechanical services station, an insulation station and a covering station. The insulation station can comprise an injector and a flowable closed cell foam dispenser for injecting the foam into a cavity defined by a frame and a drywall covering of the frame.
Another aspect of the invention provides a final assembly facility for receiving and assembling planar sections of a home according to a production schedule for custom homes. The planar sections received from a sub-assembly plant that assembles the planar sections. The final assembly facility can be located proximal to a subdivision where a plurality of the custom homes are to be situated. The final assembly facility is for constructing the homes from the planar sections according to the production schedule. The final assembly facility can be movable.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described, by way of example only, with reference to certain embodiments and the attached Figures in which:

FIG. 1 is a schematic representation of a home manufacturing system and method in accordance with an embodiment of the invention;

FIG. 2 is a schematic representation of the sub-assembly plant within FIG. 1;

FIG. 3 is representation of certain stations in the sub-assembly plant of FIG. 2 that are for framing wall sections of a house;

FIG. 4 is a representation of certain stations in the sub-assembly plant of FIG. 2 that are for applying drywall to the frame;

FIG. 5 is a representation of a transfer section in the sub-assembly plant of FIG. 2;

FIG. 6 is a representation of a station in the sub-assembly plant of FIG. 2 that is for installing building mechanical into the frame;

FIG. 7 is a representation of a station in the sub-assembly plant of FIG. 2 which is for injecting insulation into cavities of a frame of a wall;

FIG. 8 is a representation of a station in the sub-assembly plant of FIG. 2 for applying a coating, such as drywall, to the frame;

FIG. 9 is a representation of certain stations in the sub-assembly plant of FIG. 2 that is for affixing the coating to the frame and for revealing cutaways;

FIG. 10 is a representation of a transfer station in the sub-assembly plant of FIG. 2;

FIG. 11 is a representation of a staging area of the sub-assembly plant of FIG. 2;

FIG. 12 shows part of a hanging system for hanging wall sections made using the sub-assembly plant of FIG. 2;

FIG. 13 is an isometric view that show the hanging system of FIG. 12 in greater detail;

FIG. 14 is a partial sectional view that shows the hanging system of FIG. 12 in greater detail;

FIG. 15 is an isometric view showing how the hanging system of FIG. 12 can be used to store and transport wall sections made using the sub-assembly plant of FIG. 2;

FIG. 16 is an isometric view of an exemplary final assembly facility from the system of FIG. 1;

FIG. 17 is a top planar view of the final assembly facility of FIG. 16;

FIG. 18 shows an exemplary mechanism for transferring a house built using the system of FIG. 1 onto a foundation;

FIG. 19 shows how the mechanism of FIG. 18 can be removed once the house in FIG. 18 is in position on the foundation;

FIG. 20 shows a perspective view of a skate and a rail for use in moving wall sections in accordance with another embodiment;

FIG. 21 shows a front view of the skate of FIG. 20;

FIG. 22 shows a side view of the skate of FIG. 20;

FIG. 23 shows how the skate and rail system can be used to store and transport wall sections; and,

FIG. 24 shows a modified version of the final assembly facility of FIG. 17 in accordance with another embodiment,

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring now to FIG. 1, a home manufacturing system is indicated generally at 50. System 50 comprises a sub-assembly plant 54 and a plurality of final assembly facilities 58-1, 58-2, 58-3. (Collectively referred to as facilities 58, and generically as facility 58. This nomenclature is used elsewhere herein.).
Sub-assembly plant 54 receives raw building materials 74 via truck 82 and produces fully assembled wall sections 78 of each house 70 which are shipped from plant 54 via truck 83. Also produced in sub-assembly plant 54 are floor portions 80 which are also shipped via truck 83.
Each final assembly facility 58 is located proximal to a subdivision 62 or tract of land consisting of a plurality of adjacent lots 66 where houses 70 manufactured according to system 50 will be located. Lots 66 appear as squares in FIG. 1, while each house 70 appears as an “X” within a square in FIG. 1.
Sub-assembly plant 54 is typically a permanent structure having a location that is chosen in a manner so as to consider efficient access to raw building materials 74 while also considering efficient access to the plurality of subdivisions 62. Other factors influencing the location of plant 54 include more traditional considerations including labour, electricity, gas, and water. As an example, and assuming the other factors are not a significant consideration, then plant 54 can (though need not be) located so as to be substantially equidistant from all subdivisions 62 while still being accessible to raw building materials 74.
In contrast to sub-assembly plant 54, each final assembly facility 58 is typically a temporary facility that is used for assembling wall sections 78 and floor sections 80 and the roof into the house structure. Each facility 58 is also used to complete final finishes on each house 70 before depositing the finally assembled house 70 onto the foundation of its intended lot 66. Thus, it is contemplated that sub-assembly plant 54 may at any given time serve different sets of final assembly facilities 58. For example, as different subdivisions 62 are filled with houses 70, then the final assembly facility 58 associated with that subdivision 62 will be dismantled, while another final assembly facility 58 is situated near a new, empty subdivision 62. Put in other words, sub-assembly plant 54 need not be supplying each subdivision 62 at the same time, and thus, the location of sub-assembly plant 54 can be chosen to be proximal to each subdivision 62 considering that not all subdivisions are being built at a given time.
Referring now to FIG. 2, sub-assembly plant 54 is shown in greater detail. Raw materials 74 are received at plant 54 via raw-material truck 82 (or other transport) and placed into a staging area 86. Raw materials include all of the basic building components for creating wall sections 78 and floor sections 80. Such raw materials thus include the materials for framing a house, including wood or metal studs, as well as drywall, windows, insulation, and building mechanical. (As used herein, building mechanical includes all electrical, plumbing, heating ventilation and cooling (HVAC) ducts, central vacuum, telephone, cable, Ethernet, including outlets and junctions therefor, and any other components which are typically run within the interior or exterior walls or floors of a house.)
Plant 54 also includes a wall assembly line 88 that can be automated with robotic equipment or manually implemented and/or a combination of both. In a present embodiment, wall assembly line 88 includes a plurality of stations labeled as 90-1, 90-2, 90-3, 90-4, 90-5, 90-6 and 90-7. Each station 90 progressively builds one entire wall section for each house 70.
Referring now to FIG. 3, stations 90-1 and 90-2 are shown in greater detail, as raw material 74 in the form of studs 94 are constructed into a frame 98. Stations 90-1 and 90-2 are preferably fully automated, such that studs 94 are automatically loaded into machinery and assembled into frame 98, and attached to each other, using robotics and other automation equipment. Preferably, such automation equipment is also computer numerically controlled, so that the dimensions of frame 98 and the location of window and door frames are automatically supplied to the robotics. In this manner, it is intended that computer scheduling software can be used to substantially automate the scheduling aspect of the production of each frame 98 according to supplies of raw material 74 and/or the demands for particular types of wall sections for a given house 70 at a given subdivision 62.
The remaining stations 90 in line 88 are likewise configured to substantially complete an entire wall for a particular house 70. In FIG. 4, station 90-3 is shown in greater detail as a first layer of drywall (or other type of covering) is automatically applied to frame 98. Glue 102 is applied to frame 98 via a robotic glue gun 106. Sheets of drywall 110 are automatically placed into position via a vacuum assist arm 114. (Vacuum assist arm 114 can be manually operated, or automatically operated via a robot). An automatic staple gun 118 mechanically fastens drywall 110 to frame 98. A robotic cutter 122 removes portions of drywall 110 to expose doors 126 and windows 130 within frame 98.
In FIG. 5, frame 98 is shown existing station 90-3 at which point it is turned over and deposited into station 90-4 exposing the backside of frame 98. Preferably, frame 98 is turned over in an automated fashion in keeping with the automation of assembly line 88.
In FIG. 6, a cutaway of frame 98 is shown. In FIG. 6, representing station 90-4, mechanical components are run through each frame 98. (As mentioned previously, such mechanical components include all electrical, plumbing, heating ventilation and cooling (HVAC) ducts, central vacuum, telephone, cable, Ethernet, including outlets and junctions therefor, and any other components which are typically run within the interior or exterior walls or floors of a house.) In FIG. 6, representative mechanical components include an electrical outlet 134 and electrical conduit 138. Mechanical components, in a present embodiment, are typically installed manually by semi-skilled labour. When house 70 is fully assembled, the integrity of these mechanical components can be tested by skilled trades (i.e. licensed electricians for electrical components; licensed plumbers for plumbing). The exact locations, and types of mechanical components installed within frame 98 would again be done according to building design and specifications for a given house 70. The choices of mechanical materials can be traditional components used when building a house on-site in the traditional fashion, however, the mechanical materials can also be chosen to complement the environment of assembly line 88. Also, of note, the mechanical materials would be chosen to have relatively simple connections or junctions as the periphery of each frame 98, to facilitate connection to corresponding mechanical components in adjacent Wall sections 78. Such locations and types would be presented automatically via a computer screen to the individuals conducting the installations at station 90-4.
Once the mechanical components are installed in frame 98, frame 98 is advanced from station 90-4 to station 90-5. Station 90-5 is represented in FIG. 7. In station 90-5, foam insulation 146 is injected in a flowable form into cavities 142 defined by drywall 110 and studs 94 of frame 98. Foam insulation 146 will cure within each cavity 142. A presently preferred foam insulation is a closed cell foam that is commonly used to insulate buildings and homes and is often sold in preformed sheets. In a present embodiment, an overhead X-Y gantry 150 which includes an injector 154 that dispenses foam 146 into each cavity 142 according to a predefined depth and pattern. Gantry 150 and injector 154 are likewise computer controlled.
Note that while insulation 146 can be applied in any wall portion of a house 70, typically insulation 146 is only applied to the exterior walls of any given house 70. However, it can be desired to apply insulation 146 to interior walls where sound proofing is desired, such as between bathroom walls or bedroom walls. Thus, where no insulation 146 is needed for a given frame 98, gantry 150 can remain dormant for that particular frame 98.
Station 90-5 also includes a second glue gun 158 that that applies a second layer of glue 102. Glue gun 158 operates in substantially the same manner as glue gun 106.
Once the insulation 146 and glue 106 are applied at station 90-5, frame 98 is advanced from station 90-5 to station 90-6. Station 90-6 is represented in FIG. 8. In station 90-6, a covering 162 is applied to the exposed side of frame 98. A vacuum assist arm 166, much like arm 114, can be used to place covering 162 onto frame 98 in station 90-6. Where frame 98 is for an external wall, covering 162 can be a sheathing, such as plywood, oriented strand board, code board or the like. Where frame 98 is for an internal wall, then covering 162 will typically be the same as drywall 110.
At this point those skilled in the art will also now appreciate that covering 162 (and/or drywall) can in fact be any type of covering for frame 98 to present a visible surface for an interior or exterior wall.
Once covering 162 is applied at station 90-6, frame 98 is advanced from station 90-6 to station 90-7. Station 90-7 is represented in FIG. 9. In station 90-7 covering 162 is mechanically fastened to frame 98 and, if needed, cutaways, such as for doors and windows, are made. In FIG. 9, it is assumed that covering 162 is drywall, and accordingly, a staple gun 166, much like staple gun 118, is used to apply staples along covering 162 along studs 94. However, where covering 162 is another type of materials, another type of mechanical fastening device, and corresponding fasteners, other than staple gun 166, can be used. Cutaways are made by a robotic cutter 170, much like cutter 122, to expose doors and windows and the like.
As can be seen in FIG. 10, once work in station 90-7 is complete, a planar wall section 78 is now substantially complete and ready for shipping to its destination final assembly facility 58 for assembly into its respective house 70. Thus, referring again to FIG. 2, sub-assembly plant 54 also includes a staging area 174 where completed Wall sections 78 are vertically stacked and queued for eventual transport via trucks 83 to its respective final assembly facility 58. Staging area 174 is shown in greater detail in FIG. 11. Optionally, as shown in FIG. 11, further work can be done on each section 78, such as adding windows 178.
At this point it will now be reiterated to those of skill in the art that assembly line 88 is highly configurable so that each wall planar section 78 that is produced can be very unique in terms of dimensions, locations of doors and windows, type and location of building mechanical, type of external coverings. Thus, as purchaser's make requests for specific configurations of houses 70, so too can sub-assembly plant 54 be configured to schedule production runs of specific wall sections 7 accordingly. Likewise, such production runs on assembly line 88 can be scheduled so as to fill trucks 83 according to the particular final assembly facility 58 to which such trucks 83 are destined.
Various means of loading wall sections 78 into trucks 83 are contemplated. However, in a presently preferred embodiment of the invention, a hanging system is employed. Referring now to FIGS. 12-15, a novel and inventive set of removable hangers 182 are employed in order to suspend wall sections 78 during transportation in trucks 83. As best seen in FIG. 12, a series of hangers 182 are mounted to the top of each wall section 78. An appropriate number of hangers 182 are employed in order to securely support the weight of each wall section 78.
As best seen in FIGS. 13 and 14, each hanger 182 comprises a threaded eye bolt 186 that can be screwed into (or removed from) a complementary nut portion 190. Nut portion 190 has a flange portion 194 and a female-threaded portion 198 which receive the threads on bolt 186. Flange portion 194 abuts the under-side of stud 94, while female-threaded portion 198 is received within a hole that passes through stud 94. Flange portion 194 thus supports the localized weight of each stud 94. The height of female-threaded portion 198 is chosen to substantially match the depth of stud 198, or is at least less than the depth of stud 198, so as to not protrude from the top of stud 94 and thereby alter the dimensions of frame 98. Those skilled in the art will now recognize that once wall section 78 is received at facility 58, each eye bolt 186 can be removed from female-threaded portion 198, so that section 78 is left with no projections and the dimensions originally prescribed.
As best seen in FIG. 15, hangers 182 thus can be slid into a channelized overhead rail 202 within staging area 174 that align with a channelized overhead rail 206 within truck 83. Rails 202 and 206 capture the eye portion of eyebolt 186 so that rails 202 and 206 can support the weight, and allow the storage of wall sections 78. A plurality of rails 206 can be disposed in parallel and/or series within each truck 83 so that a plurality of wall sections 78 can be carried simultaneously by truck 83.
Referring again to FIG. 2, sub-assembly plant 54 also includes a flooring area 210 where sections of floor 80 are manufactured. Floor 80 can be manufactured using an assembly line like assembly line 88, or manually, as desired. However manufactured, each floor 80 constitutes all or part of a floor for each house 70. Again, each floor 80 is made according to the custom design of each house 70. Where a house 70 has multiple stories, then flooring area 210 can be used to make floors for each story. Each floor 80 is likewise shipped via truck 83 to a destination assembly facility 58.
Thus, once floors 80 and wall sections 78 are complete, they shipped via truck 83 their intended final assembly facility 58. Referring now to FIGS. 16 and 17, an exemplary final assembly facility 58 in accordance with another embodiment is shown in greater detail. As best seen final assembly facility 58 is made from a temporary structure, which in a present embodiment is a flexible material 214 held by a temporary frame made of aluminum tubing, not shown. A presently preferred flexible material 214 is the same material used to build a so-called “tennis bubble”.
Facility 58 also includes a pair of rails 218 that run the length of facility 58. Each house 70 is built upon a pair of beams 222 that run along the length of rails 218. A roof 226 for each house 70 is built at a first, beginning end of rails 218. Roof 226 is built from trusses 230 received via an inbound loading dock 234 which receives trucks 83.
Wall sections 78 and floors 80 received via dock 234 are assembled in order to build the exterior and interior shell of the first house 70-1 on rails 218. During such assembly mechanical components between each wall section 78 and floor 80 are connected. Once shell of house 70-1 is complete, an overhead crane or gantry is used to place roof 226 onto house 70-1.
Assembly facility 58 includes a plurality of stations, responsible for various stages of completion of each house. Facility 58 in FIGS. 16 and 17 is shown with eight houses, 70-1, 70-2 . . . 70-8, each at various stages of completion. Inventory 238 for each station is kept adjacent to each station. Each station is used to progressively finish each house 70. Such finishings include, for example: stairs, railings, light fixtures, plumbing fixtures, painting, doors, windows. Again, all steps taken at each station can be completely customized according to the order of the purchaser of the house 70.
Once a house is complete, such as house 70-8, it exits facility 58 via an output docking port 242 transported via a specially designed transporter 246. Transporter 246 has a flatbed which sits above a front and rear cab, both of which having controls for steering the transporter 246. Transporter 246 is also steerable via remote control, so that the operator can be outside of transporter 246 and maneuver transporter 246 while having full view of all angles of transporter 246. Transporter 246 also has steerable front and rear axles in order to be able to tightly maneuver the house 70 to its final lot 250. The flatbed of transporter 246 is below-grade to facility 58, so that rails 218 are on the same level as the flatbed of transporter 246.
As best seen in FIG. 18, house 70-8 is then carried by transporter 246 to the final lot 250 within subdivision 62 where house 70-8 is to be placed. Also as seen in FIG. 18, the flatbed of transporter 246 (not shown in FIG. 18) comprises a pair of slider-rails 254 which support beams 222 of house 70-8. House 70-8 is slid off of slider-rails 254 and onto a pre-poured foundation 258 on lot 250. Foundation 258 includes a plurality of tapered sockets 262 which are positioned to receive the distal ends of beams 222 in a complementary manner.
As best seen in FIG. 19, once house 70-8 is in position on foundation of 258, beams 222 can be removed by unfastening and removing a joining-plate 266, which separates each beam 222 into halves and allows removal of each beam 222 from the basement of house 70-8. While FIG. 19 shows two halves, it should be understood that each beam 222 can have a plurality of sections connected with a plurality of removable joining-plates.
It is to be understood that sub-sets and combinations and variations of the foregoing embodiments are contemplated and within the scope of the invention. One such variation is shown in FIGS. 20, 21 and 22, which depict a skate 300 a which can be used to maneuver wall sections 78. Skate 300 a comprises an inverted-U shaped body 304 a and a plurality of wheels 308 a mounted to the extremities of each arm 310 a of body 304 a. Wheels 308 a are rotable within each arm 310 a so that skate 300 a can be rolled along a surface, such as the floor of sub-assembly plant 54.
As seen in FIG. 20, a rail 320 a, complementary to the inverted-U shape of body 304 a can be mounted along a surface, such as the floor of sub-assembly plant 54. Skate 300 a can be rolled over rail 320 a, so that rail 320 a will guide the path of movement skate 300 a.
Referring now to FIG. 23, (a modification of FIG. 15), a modified version of truck 83 is shown and is labeled as truck 83 a. Truck 83 a includes a plurality of rails 320 a mounted along the floor thereof. In FIG. 23, overhead rail 202 of sub-assembly plant 54 is omitted, and skates 300 a are used to move wall sections 78 throughout sub-assembly plant 54. As can be seen in FIG. 23, it is contemplated that a plurality of skates 300 a can be used. Wall sections 78 rest on the surface of skates 300 a and can be slid into truck 83 a by aligning hanger 182 with overhead rail 206 within truck 83 a, and correspondingly sliding skate 300 a over the rail 320 a that corresponds with its matching overhead rail 206. In this embodiment, hanger 182 is simply for guiding and maintaining wall section 78 vertical in truck 83 a, and the weight of wall section 78 is supported by skate 300 a.
Another variation is shown in FIG. 24, which shows a modified layout of assembly plant 50 and labeled as plant 50 a. Plant 50 a is an entirely metal structure, but preferably, panelized in a manner that plant 50 a can still be disassembled from one location and reassembled at another. Plant 50 a differs from plant 50 also in the fact that plant 50 a is T-shaped. The wider section of plant 50 a can be used as a staging area for trusses 230, wall sections 78 and floor sections 80. Additionally, the wider section of plant 50 a permits multiple areas in which to assemble roves 226, with at least two such areas being shown in FIG. 24. Also shown in FIG. 24 are multiple loading docks each with a truck adjacent thereto for supplying inventory to plant 50 a.
The present invention thus provides, amongst other things, a novel system and method for manufacturing homes by providing a sub-assembly plant for producing walls and floors and one or more final assembly facilities for assembling full homes from those walls and floors and other inventory.
While the foregoing describes certain specific embodiments of the present invention, it should be understood that variations, combinations and sub-sets of those embodiments are contemplated.

Claims

1. A system for manufacturing homes comprising:

a sub-assembly plant for assembling planar sections of a home according to a production schedule for custom homes; and,

at least one final assembly facility located proximal to a subdivision where a plurality of said custom homes are to be situated; said facility for receiving said planar sections from said sub-assembly plant and for constructing said homes from said planar sections according to said production schedule.

2. The system of claim 1 wherein said planar sections include at least one of floor and walls.

3. The system of claim 1 wherein said sub-assembly plant includes an assembly line for producing at least a portion of said planar sections.

4. The system of claim 1 wherein said sub-assembly plant includes at least one of a framing station; a drywall application station; a mechanical services station; an insulation station and a covering station.

5. The system of claim 4 wherein the insulation station comprises an injector and a flowable closed cell foam dispenser for injecting said foam into a cavity defined by a frame and a drywall covering of said frame.

6. The system of claim 1 wherein planar sections comprise wall sections that are provided with a plurality of removable hangers.

7. The system of claim 6 wherein a truck for transporting said wall sections includes an overhead rail for receiving said hangers.

8. The system of claim 7 wherein said truck includes a plurality of floor rails, one said floor rail corresponding to each said overhead rail.

9. The system of claim 8 wherein said floor rails are complementary to a skate and wherein a plurality of said skates can be used to move each said wall section.

10. The system of claim 1 wherein the final assembly facility is movable.

11. The system of claim 1 wherein the final assembly facility includes at least one area for building a roof for each said home and an overhead crane for placing said roof on a respective home according to said production schedule.

12. The system of claim 1 wherein each home in said production schedule is different.

13. A truck for transporting planar sections of houses including a plurality of substantially parallel overhead rails for receiving hangers disposed within said sections.

14. The truck of claim 13 wherein the truck includes a plurality of floor rails, one said floor rail corresponding to each said overhead rail.

15. The truck of claim 14 wherein said floor rails are complementary to a skate and wherein a plurality of said skates can be used to move each said planar section.

16. A sub-assembly plant for assembling planar sections of a home according to a production schedule for custom homes, said sub-assembly plant for providing said planar sections to at least one final assembly facility located proximal to a subdivision where a plurality of said custom homes are to be situated; said facility for receiving said planar sections from said sub-assembly plant and for constructing said homes from said planar sections according to said production schedule; said sub-assembly plant comprising an assembly line for producing at least a portion of said planar sections.

17. The sub-assembly plant of claim 16 further comprising at least one of a framing station; a drywall application station; a mechanical services station; an insulation station and a covering station.

18. The sub-assembly plant of claim 17 wherein the insulation station comprises an injector and a flowable closed cell foam dispenser for injecting said foam into a cavity defined by a frame and a drywall covering of said frame.

19. A final assembly facility for receiving and assembling planar sections of a home according to a production schedule for custom homes; said planar sections received from a sub-assembly plant that assembles said planar sections; said final assembly facility located proximal to a subdivision where a plurality of said custom homes are to be situated; and for constructing said homes from said planar sections according to said production schedule.

20. The final assembly plant of claim 19 wherein the facility is movable.