Lean Manufacturing's Dangers

"Born in the factories of Toyota Motor Corp. and adopted by manufacturers worldwide, 'lean manufacturing' reduces waste, creates efficiencies and helps companies continuously shave production costs. ... Such risks are magnified as companies expand globally and offer their products in greater volume. Also, the growing technological complexity of everything from cars to electronics makes it harder for manufacturers to diagnose problems in the early stages before the issue becomce more widespread", Daisuke Wakabayashi at the WSJ, 30 January 2010, link:

http://online.wsj.com/article/SB10001424052748704343104575032910217257240.html.

I have also been uncomfortable with "just-in-time" processes as in the real world all kinds of things go wrong. We need slack in the system to avoid major breakdowns. See my 23 July 2007 post:

http://skepticaltexascpa.blogspot.com/2007/07/just-in-time-inventory.html.