Lean is an appealing concept. However, lean doesn’t allow for major surges in demand, nor does it take into account the effect that these surges or the lean process itself can have on the very well being and motivation of the people involved.
When problems occur, you end-up spending too much time fire fighting and playing catch-up and any knock-on effect is felt downstream for far too long.
Making nuts and bolts in a fully automated machine shop is an excellent example of how lean can transform production. However, the problem comes when you introduce humans into the lean process, as people can’t work flat-out all the time without being effected.
The Armed Forces is an insurance policy and not suited for ‘just in time delivery’, as such she needs a little fat around the waist.