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With so many email servers tightening down email rules etc., I find there is more and more emails bouncing back for various reasons.
In your settings the only thing I see is that after "so many" undeliverables the email address is removed.
Instead how about a SUSPEND which the user can sort through and send out notices to those who have had emails suspended. I find that many subscribers who have been caught as undeliverable, can be contacted and they usually give me a different email address to send emails to.
Having a suspend would allow a user of MLK to select those in the suspend columns and then send an email to them as a "final check" to see if there is a problem or perhaps they want to change email addresses, etc., before actually removing them from the list.
I have my MLK set for 3 undeliverables and then I send out a notice after I see 2 undeliverables, but it would sure help if this could be set up better or even more automation to handle this aspect.
Also it would be helpful if there was a spam check built into MLK that gave a spam ranking to warn users before sending email. A lot of the online email services provide this and it is great for catching an email before it is sent that could end up blacklisting you. Right now I take an email and paste it into a spam filter online which gives a ranking, but it is time consuming and it would be a nice feature for the future of MLK to better compete with online services.
Unfortunately while there are some standard formats for undeliverable report messages they are not readily used and so the majority of reports cannot be parsed in any reliable manner. This makes it difficult to definitively determine the reason for a failure.
Perhaps you could use Outlook rules to find messages that match a particular pattern and move them into a special folder. You could then use MLK's folder processing function (File > Options, Email Processing) to mark these members in some way (e.g. add them to a "Suspended" group) so you can locate them.