Case Study

Identified Failures from Inadequate Repairs

Mechanical Failures on Horizontal Grinder

Case Study

Mechanical Failures

Services Provided

Cause of Loss

Wood Chopping mulching equipment
Wood Chopping mulching equipment
Wood Chopping mulching equipment

The Situation

After a mechanical failure, ILC identified the cause of damage, assessed the extent of damage, and verified the repair costs associated with the horizontal grinder’s restoration.

Equipment Impacted

  • Horizontal Grinder

Value-Driven Solutions

Establishing Cause of Loss 

The investigation determined that repeated mechanical failures were the direct result of improper repairs, inadequate maintenance practices, and continued misuse of the equipment. Replacement parts were installed without addressing underlying issues, allowing damage to compound over time and ultimately leading to catastrophic failure.

Preventing Continued Cost Escalation and Operational Loss

By identifying that nearly $100,000 in repairs failed to correct the root causes of failure, the analysis demonstrated that ongoing investment in the grinder was ineffective. Continued operation under improper conditions accelerated deterioration and directly contributed to the unit becoming inoperable.

Wood Chopping mulching equipment

The Results

Root Cause Identified and Corrective Path Established

ILC determined that the grinder failures were caused by prolonged operation with severe vibration resulting from an improperly repaired main rotor operating out of dynamic balance. The failure was attributed to improper repairs, inadequate and untimely maintenance, and user misuse which provided a clear, defensible cause of loss and a defined corrective repair scope aligned with industry-accepted practices.

Avoided Unnecessary Replacement and Controlled Costs

ILC concluded that full machine replacement was not required to restore proper operation. By identifying and recommending essential repairs totaling $125,967, ILC helped avoid unnecessary replacement costs while addressing damage caused by prolonged operation without OEM-supported or industry-standard repairs.

Case Studies

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Fire at Chemical Processing Facility

Lead Time and Reduction by Over $15M

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Uncovered $4.5M in Betterments

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Repair vs. Replace Significantly Reduces Claim Costs

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Lead Time Cut by 14 Months, Reducing Costs by Over $1.5 Million

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Reduced Claim Cost by over $700,000

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97% Reduction in the Claim

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Reduced Claim by Nearly $1M

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Reduced Claim Costs More Than $3.5M

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Result in Reduced Claims Cost of Nearly $3M

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$11k Repair Instead of $800k Replacement

Lighting Surge at Packaging and Printing Facility

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Mechanical Breakdown at Gun Manufacturing Facility

Reduced Business Interruption by 14 weeks

Mechanical Failures on Horizontal Grinder

Identified Failures Stemming from Inadequate Repairs

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$1.6M Reduction in Pre-existing Conditions

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Water Damage with Fire Pump System

Reduced Repair Cost by almost $4k

The Experts Behind the Best Outcome.

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