11/06/2026
Our team recently completed a Kaizen event focused on improving the flow and efficiency of our Material Review Board (MRB) area. Through collaboration, process observation, and problem-solving, our staff identified opportunities to reduce waste, improve communication, and streamline material disposition.
The MRB area was experiencing excess work-in-process (WIP), delayed dispositions, unclear labeling, rework loops, and inconsistent handoffs. These challenges contributed to longer cycle times, increased inventory carrying costs, and potential shipping delays.
Our goal was to create a more organized, standardized process that moves materials from intake through final disposition more efficiently.
Two Days of Focused Improvement
Day 1 – Understand & See
Conducted a Gemba walk to observe the current MRB process.
Identified process waste, delays, and opportunities for improvement.
Used 5 Whys and Fishbone analysis to investigate root causes.
Mapped the current process and developed a future-state process.
Day 2 – Solve, Test & Disposition
Reviewed baseline data and evaluated MRB inventory by defect type.
Established clear disposition categories: Quarantine, Engineering Hold, Rework to Supplier, and Scrap.
Tested improved color-coded labels and standardized control documents.
Worked through the existing MRB inventory to ensure products received a disposition.
Our team implemented several important improvements:
Dispositioned all existing MRB products to address accumulated inventory.
Created a comprehensive MRB log with detailed information to track materials, dispositions, and follow-up actions.
Developed identification tags to clearly identify parts in the MRB area.
Specified a designated receiving location for MRB materials to improve organization and visibility.
Developed and released standardized control documents to support consistent processes.
Implemented weekly disposition reviews to prevent inventory buildup.
Assigned follow-up responsibilities to keep materials moving, including Engineering product reviews and Supply Chain actions for replacement orders.
The work doesn't stop with the Kaizen event! The MRB log is now maintained with detailed information and shared with the appropriate team members during warehouse meetings. Assigned action items help ensure accountability and timely follow-through.
This Kaizen event demonstrates the power of teamwork, employee engagement, and continuous improvement. By identifying problems, challenging existing processes, and implementing practical solutions, our staff has taken important steps toward a more efficient, organized, and proactive MRB process.
Small improvements can lead to big results.
