This of course becomes a moot issue if the developers will create an interface for defining, and causing to be constructed, an army that does not require existing units to be joined together by hitting V.
If they will allow a player to set up an army template by indicating what units the army should have in it, and then allow that to start being built simply by tapping into existing production capacity, just like reinforcing existing armies is done, that would be extremely helpful. It doesn't make sense to say that micromanaging individual units is over, and the future is manipulating whole army metaunits, and then require me to dork around with individual units in order to create the army in the first place.
I've run into the problem described in the OP in each of my last two games, since a fellow player in another thread mentioned to me how to use the reinforcement mechanic. In these games I created two or three armies by banding together output from my first factories, and then as soon as I built several T2 units, I added them to the existing armies, then went into the build menu for each army and told it to reinforce the army with various numbers of different units.
At this point every single unit produced by each factory came off the line already belonging to an army. I wanted to create a new army, but without disbanding an existing army, I couldn't do it, except for a bug: the factories had a couple of units that had been built as requested by one of my existing armies, but somehow had come off the line unbound, and were just sitting there.