Patent Application
20080004931
Embodiments of the present invention include improved housewrap packaging approaches. By providing optimized shippable container configurations, it is possible to quickly and inexpensively provide housewrap product to a contractor, installer, retailer, homeowner, or any desired recipient. Shippable container configurations can be selected so as to maximize cost and efficiency with outsourced logistics providers such as UPS® or DHL®. Relatedly, embodiments of the present invention also include improved housewrap distribution approaches. A host computer can receive a housewrap order via the phone or internet. The host computer can then transmit the order to a packaging site and to a logistics provider to package a customized housewrap package and deliver it to a specific location. In some cases, the distribution chain will not include certain touch points such as local or regional distributors. These new techniques for selling, packaging, and distributing housewrap can optimize distribution costs, and in some embodiments provide for a 24 hour delivery format.
Turning now to the drawings,
In some cases, a master roll of containing a bulk 9′×15,000 sheet of housewrap is shipped from a production site of a housewrap manufacturer to a packaging site warehouse. The packaging site may inventory any number of master rolls. In some cases, the number of rolls inventoried will be selected so as to maximize packaging efficiency. As seen in step 130, the method can include processing a sheet of housewrap at the packaging site according to the set of housewrap specifications so as to produce a housewrap package. For example, a master roll, which may or may not include generic printing, can be processed at the packaging site according to the set of housewrap specifications. In some embodiments, the packaging site includes a converting area where custom length sheets are unrolled and cut from the master roll. The custom length sheets may be wrapped around tube cores, rolled into cylinders without a core, folded into desired shapes and sizes, and the like. A housewrap package may include one or more shippable containers filled with any suitable combination of custom length sheets. Shippable containers can include boxes, sleeves, and the like. In some cases, the housewrap package includes a plurality of 2′×4′ boxes, which can be conveniently placed on a 4′×4′ pallet. Any of a variety of package delivery services or modalities may be used to transport a housewrap package from a packaging site to a logistics hub, as depicted in step 140.
Step 150 includes transmitting the set of delivery instructions from the host computer to a logistics computer of a logistics provider, such that the logistics provider is instructed to deliver the housewrap package from the logistics provider hub to the recipient according to the set of delivery instructions. For example, the logistics provider may be instructed to deliver a box, pallet, or other housewrap package shipment to a contractor, a homeowner, a home improvement product retailer, a job site, and the like. In some cases, part of the housewrap specification may be transmitted to the logistics computer, and/or part of the delivery instructions may be transmitted to the packaging computer. Optimization algorithms may be included or implemented by host computer, packaging computer, and/or logistics computer to achieve, for example, economical or efficient packaging and shipping configurations based on the housewrap order. Communication between host computer, packaging computer, and logistics computer can be effected via any of a variety of combinations of electronic, written, verbal, or human-mediated means.
Step 220 includes receiving a payment instruction. The customer may wish to pay via credit card such as Visa® or MasterCard®, debit, check, or any other acceptable payment method. The payment instruction may also include or reflect discounts for the customer. For example, a licensed building contractor or a customer associated with a particular home builder may receive a 15% discount from the standard price of the housewrap. Step 230 includes receiving a set of delivery instructions. In some cases, the customer may select desired or preferred shipping container sizes or shapes. For example, the customer may choose a preferred shipment configuration for housewrap packages that are folded, rolled, with tube cores, without tube cores, and the like.
Specifications and instructions such as sheet dimensions, printing options, accessories, and the like may be represented by or associated with an SKU or other input field as show in Table 1.
A web-based interface for placing orders over the internet can incorporate such input fields. Web-based ordering systems may include an ordering component, a cash management component, an order fulfillment component, and the like. These and other related embodiments provide a convenient and efficient approach for ordering housewrap. These techniques are well suited for producing a custom job lot of housewrap packages, and provide branding and co-branding opportunities, advertising value, and name recognition for contractors, builders, retail establishments, and the like.
Embodiments of the present invention contemplate that housewrap packages may contain housewrap sheets in any of a variety of dimensions. For example, housewrap sheets or portions thereof may have a length dimension between a range from about 20′ to about 100′. Similarly, housewrap sheets or portions thereof may have width dimensions between a range from about 3′ to about 20′. Typically, 8′, 9′, 10′, 12′ widths, and the like may be used for single story homes. Embodiments also include 18′, 20′, 24′, 28′ widths, and the like, which may be used for multi-story homes where a shingled or overlapped approach is not desired. It is also appreciated that housewrap package embodiments include shippable containers having any of a variety of dimensions. Often, a particular logistics provider can have one or more preferred, minimum, or maximum shippable package dimensions. For example, a logistics provider may offer bulk, discounted, or otherwise favorable rates for shippable packages having certain length, width, height, circumference, weight, or other dimensions or attributes. Similarly, a logistics provider may charge a premium rate for shippable packages having certain length, width, height, circumference, or other dimensions. Shippable package containers can be selected to minimize freight rates or to optimize shipping variables. In some cases, methods and system embodiments of the present invention determine and/or provide improved or optimized space utilization in a transport vehicle carrying a package, at a retail outlet, at a lumber yard, and the like.
In some cases, a customer may wish to select or customize dimensions of the housewrap sheets. Similarly, a customer may wish to select or customize dimensions of the shippable packages into which the housewrap sheets or portions thereof are packaged. For example, a home improvement retail outlet store such as Home Depots may wish to order a set of housewrap sizes having shorter lengths for easier installation (e.g. 9′×30′, 12′×30′, and 20′×30′) in housewrap packages having dimensions such that consumers visiting the store can easily handle the package, pick it up, and place it in their shopping cart. Relatedly, Home Depot® or other stores may wish to order housewrap packages that can be easily stored on their shelves. Some home improvement retailers have steel frame shelving units with certain dimensions (e.g. 8′ wide, 3′ to 8′ tall, 4′ deep). Advantageously, these retailers and other customers can select housewrap package configurations so as to optimize shelf space, thus adding another layer of efficiency and organization, and cost savings can be passed along to the consumer. The customer may also wish to configure their order so as to minimize shipping rates or to optimize any of a variety of distribution variables. In some cases, shipping package containers can be configured for use at a jobsite beyond their use as a shipping instrument. In some embodiments, a shippable container is made of corrugated plastic in a configuration that can be used as a sill pans. Shippable containers can have any of a variety of shapes, including without limitation cylindrical shapes, triangular shapes, rectangular shapes, sleeves, pouches, envelopes, and the like, or any combination thereof. Shippable containers may include flexible, semi-flexible, and rigid materials. Shippable containers may be manufactured from any of a variety of construction matter, including cardboard, paper, plastic, polymers, and the like. In some cases, a shippable container may be constructed of bubble wrap.
According to another embodiment, a 9′×100′ housewrap sheet can be cut into three equal lengths of 9′×33⅓′. Each of these three portions can be folded lengthwise twice, to provide three folded sheets of 2¼′×33⅓′. The three sheets can be rolled and placed into a shippable container box along with two rolls or tape. The shippable container may have dimensions of a 8″×8″×30″ box. 40 of these boxes may be placed on a 40″×48″ pallet, and 20 loaded pallets can be placed in a freight container. The freight container may be transported from a packaging site to a customer or other destination. In this way, 800 boxes, the equivalent of 800 100′ housewrap sheets, can be conveniently and economically shipped to virtually any desired location. By comparison, in some cases the cost for shipping classic packaged rolls of 9′×100′ housewrap can be up to ten times the cost for shipping a boxed folded housewrap sheet as described above. In some embodiments, shippable containers may be covered in weather resistant wrap, stretch wrap, and the like. Such coverings can provide protection to housewrap packages when exposed to the elements, which often occurs after packages are delivered to a retailer and before the packages are moved to a protected location.
For example, a customer may wish to order housewrap to cover a house having walls 10′ in height, and a perimeter of 250′, for a total area of approximately 2500 square feet. The customer may wish to receive the housewrap package, which may contain one or more individual packages, in shippable containers not exceeding a 15″ length, a 10″ height, and a 10″ width. The customer may also wish to receive the housewrap package between July 6 and July 8, to be delivered at a particular job site address. A computer or processor can determine a housewrap package configuration for the shipment, based on one or more logistics provider pricing schedules. For example, one logistics provider may not be able to deliver a housewrap package according to this particular housewrap order, whereas another logistics provider may be able to perform the delivery. In another example, a particular logistics provider may be able to perform the delivery in 12″×10″×10″ containers at a first cost, or in 15″×8″×8″ containers at a second cost, where the first cost is greater than the second cost. The computer, in implementing an optimization algorithm to minimize cost, may decide to configure the housewrap package for shipment in 15″×8″×8″ containers. In a related example, a particular logistics provider may be able to perform the delivery in 12″×10″×10″ containers on a first delivery date, or in 15″×8″×8″ containers on a second delivery date, where the customer's preferred delivery date is closer to the first delivery date than the second delivery date. The computer, in implementing an optimization algorithm to approach a desired delivery date, may decide to configure the housewrap package for shipment in 12″×10″×10″ containers. It is appreciated that optimization algorithms can be designed to consider any type of packaging or distribution variable.
In some cases, a customer may wish to order housewrap based on building plan drawings or specifications. A housewrap order for a single house may include data that reflects or correlates with a variety of housewrap pieces having various dimensions, such as width, length, and the like, optimized or otherwise customized for the particular house. This data can correspond with the building plan drawings or specifications. For example, a housewrap order can contain instructions for a housewrap package to include multiple precut pieces to cover entire wall sections. Each piece can be a specific width and length. In some cases, the dimensions of the housewrap pieces can be determined by an optimization algorithm, based on the building plan drawings or specification, optionally in conjunction with other factors such as a set of delivery instructions, a logistics provider pricing schedule, and the like. For example, an algorithm can be used to determine the optimum piece sizes that economically fit into shipping boxes. An algorithm can also generate assembly or installation instructions based on the housewrap order. The precut pieces can be tagged or marked to identify their application locations, and the assembly or installation instructions can refer to various pieces in the housewrap package according to their tagging or marking identification.
Algorithms for optimizing housewrap packages based on building plan drawings or specifications may be included in or implemented by one or more modules of a host computer, a packaging computer, and/or a logistics computer. Methods and systems for determining the precut sizes of housewrap to be packaged can involve modules or means configured to read or input such plan drawings or specifications, and to determine practical precut piece sizes to fit the building. The precut sizes can be selected or determined so as to provide economical package and shipping configurations.
Housewrap sheets and packages may include any of a variety of housewrap brands, including Gorilla Wrap™, which is a translucent, non-perforated, nonwoven polymeric housewrap produced by Johns Manville's Engineered Products Group. Gorilla Wrap™, is tear resistant, and contains ultraviolet inhibitors. The housewrap reduces potential for bulk water penetration and allows trapped moisture to escape, thus reducing concerns about mold and mildew growth. In addition, it keeps wood sheathing dry, reducing the potential for rot and degradation within the wall cavity.
It will be appreciated that the systems and method described herein can be utilized for any of a variety of building materials including roofing underlayment and other drainage plane materials. Such materials are often water repellent or water resistant, are located behind the cladding of a house, and are designed to drain water that passes through the cladding, siding, roofing, or other material that covers a house.
Although certain system, device, and method embodiments have been disclosed herein, it will be apparent from the foregoing disclosure to those skilled in the art that variations, modifications, alternative constructions, and equivalents of such embodiments may be made without departing from the true spirit and scope of the invention. Therefore, the above description should not be taken as limiting the scope of the invention which is defined by the appended claims.
