System for production of standard size dwellings using a satellite manufacturing facility

Abstract

The system for manufacturing standard size dwellings comprises a network of facilities, sited to maximize the efficiency of the product and materials flows. In particular, one or more manufacturing facilities are used to manufacture subassemblies and supply materials for use in assembling a standard size dwelling in a factory environment. These manufactured subassemblies and materials are transported to one or more satellite manufacturing facilities, each of which are located proximate to a location where a large number of dwellings are to be built. The satellite manufacturing facilities function to integrate the received subassemblies and materials together to create a standard size dwelling, which is then transported to the foundation where the dwelling is to be sited. The satellite manufacturing facilities can optionally manufacture subassemblies, such as a roof subassembly, where appropriate as part of the dwelling assembly process.

1 . A system for constructing standard size dwellings substantially in their entirety in a factory environment in at least one satellite manufacturing facility that is located remotely from at least one master production facility, said satellite manufacturing facility comprising: 
 at least two subassembly staging areas for receiving said constructed predetermined subassemblies from said at least one master production facility;    hoisting means operational in at least one of said subassembly staging areas for transporting said constructed predetermined subassemblies for incorporation into a standard size dwelling being assembled in said satellite manufacturing facility; and    wherein said standard size dwelling is transported through said satellite manufacturing facility to assemble said standard size dwelling, using said predetermined subassemblies from said at least two subassembly staging areas.    
   
   
       2 . The system for constructing standard size dwellings of  claim 1  wherein said hoisting means comprises: 
 at least one crane that traverses said at least one subassembly staging area and a section of a dwelling assembly site for transporting said constructed predetermined subassemblies from said at least one subassembly staging area into said dwelling assembly site for incorporation into a standard size dwelling being assembled in said satellite manufacturing facility.    
   
   
       3 . The system for constructing standard size dwellings of  claim 1  wherein a first of said subassembly staging areas comprises: 
 means for constructing a floor subassembly comprising an integral base frame for placement on a transport element located in a dwelling assembly site.    
   
   
       4 . The system for constructing standard size dwellings of  claim 3  wherein a second of said subassembly staging areas receives said constructed predetermined subassemblies from said at least one master production facility comprising a plurality of panelized wall assemblies for assembly on to said floor subassembly located on a transport element located in said dwelling assembly site to create a partially assembled standard size dwelling.  
   
   
       5 . The system for constructing standard size dwellings of  claim 4  wherein a third of said subassembly staging areas receives said constructed predetermined subassemblies from said at least one master production facility comprising a plurality of panelized wall assemblies for installation in the partially completed standard size dwelling located on a transport element located in said dwelling assembly site.  
   
   
       6 . The system for constructing standard size dwellings of  claim 5  wherein a fourth of said subassembly staging areas is used to construct a roof subassembly for assembly on to said partially completed standard size dwelling located on a transport element located in said dwelling assembly site.  
   
   
       7 . The system for constructing standard size dwellings of  claim 4  wherein a third of said subassembly staging areas is used to construct a roof subassembly for assembly on to said partially completed standard size dwelling located on a transport element located in said dwelling assembly site.  
   
   
       8 . The system for constructing standard size dwellings of  claim 3  wherein said hoisting means, located in said second subassembly staging area, transports finish elements to be installed in a first floor of said standard size dwelling.  
   
   
       9 . The system for constructing standard size dwellings of  claim 1  wherein said hoisting means comprises: 
 at least one crane that traverses said at least one subassembly staging area and a section of a dwelling assembly site and a subassembly production area that are adjacent said subassembly staging area for transporting said constructed predetermined subassemblies from said at least one subassembly staging area into said dwelling assembly site for incorporation into a standard size dwelling being assembled in said satellite manufacturing facility and into said subassembly production area.    
   
   
       10 . The system for constructing standard size dwellings of  claim 1  wherein said satellite manufacturing facility further comprises: 
 a roofing subassembly staging area, for constructing a roof subassembly for assembly on to said partially completed standard size dwelling located on a transport element in said satellite manufacturing facility.    
   
   
       11 . The system for constructing standard size dwellings of  claim 1  wherein said satellite manufacturing facility further comprises: 
 a roofing subassembly staging area, for constructing a roof subassembly for assembly on to said partially completed standard size dwelling located on a transport element external to said satellite manufacturing facility.    
   
   
       12 . The system for constructing standard size dwellings of  claim 1  further comprising: 
 at least one master production facility located remotely from said satellite manufacturing facility for constructing predetermined subassemblies for said standard size dwelling.    
   
   
       13 . A method of constructing standard size dwellings substantially in their entirety in a factory environment in at least one satellite manufacturing facility that is located remotely from at least one master production facility, said satellite manufacturing facility comprising: 
 receiving in at least two subassembly staging areas said constructed predetermined subassemblies from said at least one master production facility;    transporting, using hoisting apparatus operational in at least one of said subassembly staging areas, said constructed predetermined subassemblies for incorporation into a standard size dwelling being assembled in said satellite manufacturing facility; and    transporting said standard size dwelling through said satellite manufacturing facility to assemble said standard size dwelling, using said predetermined subassemblies from said at least two subassembly staging areas.    
   
   
       14 . The method of constructing standard size dwellings of  claim 13  wherein said step of transporting, using hoisting apparatus, comprises: 
 transporting, using at least one crane that traverses said subassembly staging area and a section of a dwelling assembly site, said constructed predetermined subassemblies from said subassembly staging area into said dwelling assembly site for incorporation into a standard size dwelling being assembled in said satellite manufacturing facility.    
   
   
       15 . The method of constructing standard size dwellings of  claim 13  further comprising: 
 constructing, in a first of said subassembly staging areas, a floor subassembly comprising an integral base frame for placement on a transport element located in a dwelling assembly site.    
   
   
       16 . The method of constructing standard size dwellings of  claim 15  further comprising: 
 receiving, in a second of said subassembly staging areas, said constructed predetermined subassemblies from said at least one master production facility comprising a plurality of panelized wall assemblies for assembly on to said floor subassembly located on a transport element located in said dwelling assembly site to create a partially assembled standard size dwelling.    
   
   
       17 . The method of constructing standard size dwellings of  claim 16  further comprising: 
 receiving, in a third of said subassembly staging areas, said constructed predetermined subassemblies from said at least one master production facility comprising a plurality of panelized wall assemblies for installation in the partially completed standard size dwelling located on a transport element located in said dwelling assembly site.    
   
   
       18 . The method of constructing standard size dwellings of  claim 17  further comprising: 
 constructing, in a fourth of said subassembly staging areas, a roof subassembly for assembly on to said partially completed standard size dwelling located on a transport element located in said dwelling assembly site.    
   
   
       19 . The method of constructing standard size dwellings of  claim 16  further comprising: 
 constructing, in a third of said subassembly staging areas, a roof subassembly for assembly on to said partially completed standard size dwelling located on a transport element located in said dwelling assembly site.    
   
   
       20 . The method of constructing standard size dwellings of  claim 15  further comprising: 
 transporting, using said hoisting means located in said second subassembly staging area, finish elements to be installed in a first floor of said standard size dwelling.    
   
   
       21 . The method of constructing standard size dwellings of  claim 13  further comprising: 
 transporting, using said hoisting apparatus that traverses said at least one subassembly staging area and a section of a dwelling assembly site and a subassembly production area that are adjacent said subassembly staging area for transporting said constructed predetermined subassemblies from said at least one subassembly staging area into said dwelling assembly site for incorporation into a standard size dwelling being assembled in said satellite manufacturing facility and into said subassembly production area.    
   
   
       22 . The method of constructing standard size dwellings of  claim 13  further comprising: 
 constructing a roof subassembly for assembly on to said partially completed standard size dwelling located on a transport element located in said dwelling assembly site.    
   
   
       23 . The method of constructing standard size dwellings of  claim 13  further comprising: 
 constructing a roof subassembly for assembly on to said partially completed standard size dwelling located on a transport element external to said satellite manufacturing facility.    
   
   
       24 . The method of constructing standard size dwellings of  claim 13  further comprising: 
 constructing, in at least one master production facility located remotely from said satellite manufacturing facility, predetermined subassemblies for said standard size dwelling.