Housing manufacturing system and method

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.

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.