What is this article about?
A sudden production stoppage caused by unforeseen damage or even a major loss can have drastic consequences for a manufacturing company: machines break down, valuable equipment is damaged, and operations are brought to a standstill for an indefinite period. These crucial moments show how well the company is protected against risks. A look at the insurance coverage and determining the actual insured value of the affected operating equipment then becomes the key measure.
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More InformationHowever, a problem often only becomes apparent when a claim occurs: if there is underinsurance, the compensation can be significantly reduced, which makes it difficult to resume production. In order to avoid this situation and to clarify possible differences at an early stage, a regular, precise review of the insured value by an independent expert is essential.
The article addresses essential aspects of the topic of “underinsurance” in the event of major losses ( fire , machine breakdown) in manufacturing companies.
What are the insured value and the insured sum?
In the case of damage, particularly major damage, in the area of “machinery, mechanical engineering, systems”, the insurance value is determined by experts or appraisers.
Significance for manufacturing companies and mechanical engineering
Manufacturing companies and the mechanical engineering sector are usually insured against machine breakdown and fire. The insurer is usually
- the “ General Conditions for Fire Insurance (AFB 2010) ” or
- the “ General Conditions for Machinery Insurance of Stationary Machines (AMB 2020 )”
Sometimes there are deviations from this with individual agreements.
In both cases, the insured value and the insured sum are of great importance. In the insurance industry, the terms insured value and insured sum have different meanings.
General definition of insurance value
The insurance value is defined as follows:
... in fire insurance
In the ” General Conditions for Fire Insurance ” various cases are defined for
- buildings and
- movable property.
Depending on the circumstances, the insurance value may be
- new value,
- Value,
- fair value.
For an explanation of the various value concepts, please refer to the “Value Concepts” page.
... in machinery insurance
In the “ General Terms and Conditions for Machinery Insurance of Stationary Machines (AMB 2020) ”, the insured value is defined as the new value.
However, various exceptions are defined in paragraph 6 “ Insured and uninsured costs ”.
General definition of the insured sum
The insured sum is defined as follows:
She is the
Upper limit for the insurance payment in the event of a claim
and should
ideally correspond to the insurance value.
underinsurance
Is the
If the sum insured at the time of the insured event is lower than the insured value, there is underinsurance.
This means that the policyholder who suffers damage as a result of an event will only be compensated in proportion.
In case of underinsurance, the compensation will be reduced according to the following calculation formula:
Compensation = amount of damage * insured sum / insured value.
Real problems
Often the sum insured, which is important for the conclusion of the contract and which of course also influences the premiums to be paid by the policyholder, is estimated or taken from the asset management of the accounting department, i.e. the book values. However, this never meets reality and usually leads to negative surprises in the event of a claim.
Check the insured value and sum insured regularly
In property insurance for industrial companies, the insured value and the insured sum are particularly important, as they are crucial for insurance coverage and financial security in the event of a loss.
Figure 1 shows the development of the producer price index for industrial products for machinery in Germany in relation to the base year 2020, the beginning of the corona pandemic.
Since then, prices for machines have been rising continuously and especially significantly during the Corona period.
It is therefore important for manufacturing companies to
Knowing the insurance value and ideally determining it regularly
Therefore, it is important to:
- Avoiding underinsurance: Industrial companies usually have very valuable assets, such as production facilities, machines or stocks. If the insured value is not determined correctly and the insured sum is set too low, underinsurance exists. In the event of a claim, the insurance would only cover part of the damage and the company would have to cover the rest itself, which can mean enormous financial burdens.
- Avoiding overinsurance: If a company sets the insured sum higher than the actual insured value, it will pay unnecessarily high premiums. Since the insurance only replaces the actual value in the event of a claim and not the excessive amount, unnecessary costs arise for the company.
- Accurate financial protection in the event of damage: The insured value serves as a basis for realistically depicting the replacement costs or repair costs in the event of damage. For industrial companies, a total loss or partial loss can have major economic consequences, which is why an accurate determination of both values ensures that the company is compensated quickly and as fully as possible in order to be able to maintain or resume operations.
The major loss event in manufacturing companies (machinery, plants, operating equipment)
In the end, every damage is about time and money. It is important for the affected company (policyholder) that its contracts with customers are adhered to despite the loss event. At the same time, machines have to be newly procured or refurbished. The options depend very much on the extent of the damage determined. If, for example, the determined insurance value is lower than the insured sum agreed with the insurer, deductions will result.
A major loss event in mechanical engineering is a serious damage event that causes major financial losses and significantly impairs or completely paralyzes a company’s production process. Such events can have various causes and often affect expensive and complex machines and equipment that are crucial for production. Some examples of typical major loss events in mechanical engineering are:
- Machinery breakdown : An unexpected failure or serious damage to one or more key machines, often caused by technical defects, overloading, operator error or material defects. Machinery breakdown can be particularly costly, requiring expensive repairs or even complete replacement and severely affecting production.
- Fire and fire damage : A fire in the production area can not only destroy machinery and equipment, but also affect the entire building and inventory. Such damage often requires extensive restoration measures and can lead to significant production losses.
- Natural damage : Natural disasters such as floods, storms or inundations can flood or damage machine halls. Such damage is serious because, in addition to destroying the infrastructure, it can also seriously impair the functionality of the machines.
- Explosions : In industrial plants that handle flammable materials or machines operating under high pressure, explosions can cause serious damage. These events often affect not only the machines themselves but also the surrounding areas and can endanger the safety of the entire plant.
- Contamination or chemical reactions : In companies that work with chemicals, improper handling or technical malfunctions can lead to chemical reactions and contamination. This damage often requires expensive cleaning and repair work and can have long-term consequences for production.
A major loss event usually leads not only to
high direct damage costs for repairs and replacements,
but also to
significant business interruption costs
due to production losses and lost revenues.
What usually happens when a loss event or major loss event occurs?
- After a major loss event in mechanical engineering occurs, the authorities first investigate. If the scene of the loss is permitted to be entered after the investigation has been completed, the insurers examine the claim.
Here is the process in chronological order:
- Initial measures and alarm by the company
- Alert: The affected company immediately reports the incident to relevant emergency services such as fire brigade, police and possibly rescue services.
- Emergency measures: Initial safety measures are taken, such as evacuations, fire extinguishing and cordoning off the affected area to protect people and property.
- (Simultaneously) reporting the damage to the insurance company
- Notification of damage by the company: The affected company immediately reports the damage to the insurance company and provides initial information on the extent of the damage and possible causes.
- Provision of initial documents: The company provides photos, initial official reports and internal company documents to prove the damage.
- official measures
- Securing the scene of the accident: Police and fire brigade secure the area, prevent further access and ensure that there is no danger to people.
- Investigation into the cause of the fire or damage investigation: If necessary, a forensic team will be called in to determine the cause of the damage, such as a fire or explosion. If negligence or a criminal offense is suspected, a detailed report will be requested.
- Documentation by the authorities: The authorities create comprehensive documentation of the extent of the damage and the cause, which later serves as the basis for insurance and legal assessments.
- assessment by the insurer
- Appointment of an expert: The insurer sends a claims adjuster and an (external) expert, often a machinery expert, to assess the damaged machinery and equipment, usually with the following assignment:
- determination of the cause,
- Determination of the amount of damage and responsibility,
- determination of the insurance value
- Damage assessment and evaluation: The expert documents the damage in detail, determines the cause and establishes the extent of the damage. Determination of the insured value and the amount of compensation: The insurance company checks the insured value of the damaged machines and equipment in order to determine the actual amount of compensation. Possible underinsurance is also assessed.
- Appointment of an expert: The insurer sends a claims adjuster and an (external) expert, often a machinery expert, to assess the damaged machinery and equipment, usually with the following assignment:
- Coordination and communication between insurer and policyholder
- Damage discussion: The insurance company discusses the results with the company and clarifies any open questions about the damage, the cause and the next steps.
- Checking for co-insurance and distribution issues: If several insurers or policies are involved, they will clarify the distribution of the compensation payment and agree on the procedure.
- decision on compensation payments
- Partial payments: Sometimes partial payments are made by the insurer before the final determination of the amount of the loss and the insured value.
- Calculation of the compensation payment: The insurer determines the amount of compensation based on the extent of the damage and the insurance conditions.
- Settlement: After checking the eligibility and calculating the amount, the payment is released and paid out to the company.
- Start of restoration and repair by the company
- Damage repair: With the compensation payments received, the company starts the repair or replacement of the damaged machines and equipment.
- Insurer monitoring: Insurers often maintain insight into the repair process to ensure that the restoration meets the agreed terms.
- final documentation and evaluation
After all loss-related measures have been completed, the insurer prepares a final report and fully documents the event. In many cases, the lessons learned from the loss event are used by both the company and the insurer to develop measures to minimize risk and prevent future major loss events.
What should you do if the policyholder assesses the amount of damage differently than the insurer?
The example images in this article clearly show that the damage caused by a major loss event is always significant. In this context, it is not unusual for the affected policyholder’s ideas regarding the amount of the claim settlement to differ greatly from those of the insurer.
After a loss event, the policyholder is under considerable pressure, as time and financial resources are at stake. It is crucial for the affected company to maintain its contractual obligations to its customers even in crisis situations. At the same time, affected machines, systems or operating equipment must either be replaced or repaired, with the scope for action available largely depending on the extent of the loss determined.
Is the
sum insured lower than the insured value
at the time of occurrence of the insured event,
underinsurance.
The policyholder therefore has a strong interest in ensuring that the determined insured value after the loss does not exceed the agreed insured sum if possible.
In order to ensure a more reliable valuation in the event of damage, the policyholder will often seek the expert procedure . This procedure offers the opportunity to clarify the amount of damage and the insurance value transparently and objectively, which benefits both the policyholder and the insurer.
Expert procedure
An expert procedure is a fixed dispute resolution mechanism that is often included in insurance contracts – especially in industrial insurance. It is used when, after a loss, there is a disagreement between the policyholder and the insurer about the amount of the loss or the cause of the loss.
Such procedures are particularly important in mechanical engineering, where damage to expensive machines can quickly run into the millions. Policyholders and insurers can have different opinions on claims settlement, i.e. how high the actual damage is, what costs must be reimbursed or whether the repair measures are appropriate. An expert procedure helps to clarify these differences in a factual and objective manner during claims settlement and supports professional claims management.
Conclusion
If a damage event occurs in a manufacturing company, machines, systems and operating equipment are often significantly affected, which can significantly affect production. In a liability case, the insurer of the person responsible will pay the current value or replacement value. In the case of damage caused by fire or machine breakdown, however, the settlement is made through the company’s own insurer, such as fire insurance or machinery insurance. The insured value is determined by an insurance expert or on behalf of the insurance company.
If this value is higher than the sum insured agreed between the policyholder and the insurance company, there is underinsurance and the compensation will be reduced. To avoid this risk, manufacturing companies should
Policyholders and insurers may have different opinions on the settlement of claims, i.e. how high the actual damage is, what costs need to be reimbursed or whether the repair measures are appropriate. An expert procedure helps to clarify these differences in a factual and objective manner during the settlement of claims and supports professional claims management.
Have the insurance value checked regularly,
to avoid any unpleasant surprises in the event of a claim. An expert procedure is advisable in the event of a claim, so that an independent expert can examine the circumstances and clarify any deviations from the insurance expert’s report.
Recommendation:
Check the values of the machines, equipment and operating facilities in the plant at regular intervals. If necessary, involve experts for an assessment.
