Rethinking Industrial Risk: How AI is Reshaping Insurance in manufacturing

How Uniquon enabled a specialist insurer to transform underwriting and risk management through predictive Artificial Intelligence

For a leading commercial insurer serving the industrial and manufacturing sectors, underwriting was becoming increasingly complex. Clients operated in volatile environments, where downtime events, system failures and latent risks could result in significant claims. Yet, policies were still priced and issued based on static data and backward-looking models.

The insurer partnered with Uniquon to shift from reactive claims management to proactive risk orchestration. The result was a bespoke AI-driven platform for industrial underwriting and predictive loss prevention—enhancing underwriting precision, minimising claims, and positioning the insurer as a strategic partner to its clients.

The Challenge

The insurer served a client base with critical infrastructure—power generation plants, logistics hubs, and advanced manufacturing sites. These environments carried elevated exposure to mechanical breakdown, fire risk, and operational interruption. Traditional actuarial approaches relied on historical claims data and generic industry classifications, often failing to capture the unique operational realities of each site.

This led to overly conservative pricing in some cases and underexposure in others, while underwriting remained heavily manual and document-driven. Clients were frustrated by long lead times and limited visibility into how their risk profiles were assessed.

Our Solution

Uniquon delivered a modular, AI-powered solution with two core capabilities:

• Dynamic Underwriting Engine: Machine learning models processed a wide array of structured and unstructured data—from asset-level performance metrics and maintenance logs, to historical incident reports and environmental data. The system generated real-time risk scores per site, enabling underwriters to adjust premiums, exclusions and cover levels with unprecedented precision.

• Continuous Risk Monitoring: IoT feeds from on-site sensors (temperature, vibration, pressure, flow) were integrated into the platform to detect anomalies, degradation patterns, and early indicators of failure. Predictive alerts were issued to clients and loss prevention teams before issues escalated—dramatically reducing claim frequency and severity.

Underwriters were equipped with automated risk reports and dashboards, offering full visibility into the insured asset portfolio. The system supported scenario modelling, co-insurance planning, and broker collaboration.

Implementation Strategy

The programme was rolled out in four tightly coordinated phases:

1. Data Aggregation and Modelling: Client datasets—claims, inspections, engineering reports—were ingested and normalised to train and calibrate the models.

2. Sector-Specific Risk Profiling: Tailored scoring logic was developed for key verticals, including food processing, chemical production, and precision manufacturing.

3. Pilot Deployment: A closed pilot with 20 high-risk policies compared AI-generated scoring and live risk signals to traditional assessments. The improvement in accuracy was immediate.

4. Operational Rollout: Full deployment included broker access, client dashboards, and integration with existing policy administration systems.

The Results: turning data into actionable insights for industrial risk mitigation

Within months of launch, the insurer achieved:

• 30% reduction in preventable loss claims across monitored facilities

• Increased pricing accuracy, lowering combined ratios while improving client retention

• 40% faster underwriting cycles, driven by automated analysis and pre-validated data

• Enhanced broker and client satisfaction, through greater transparency and value-added insights

The insurer transitioned from a passive risk taker to an active, data-driven risk partner—strengthening client relationships and competitive differentiation.

Why Uniquon

At Uniquon, we don’t just apply AI to risk—we redefine how industrial risk is understood, managed, and priced.

Our platforms turn data into foresight and underwriting into strategy. By combining advanced modelling, real-time sensing and seamless digital experience, we enable insurers to evolve from protection to prevention.