On average, the fan industry experiences warranty failures at the rate of 1.5%-2% in India. In fact, the figure is as high as 7% in cases where the Fan Manufacturers do not have a stringent check in place to assure raw material quality.

Every warranty failure is a cost to your business. This cost is not directly in monetary forms but in multiple ways such as:

• Loss of trust among customers.
• Brand perception and reliability get skewed in customers’ eyes.
• Monetary loss

 

Moreover, if you manufacture other electrical products along with fans, this loss of brand credibility is not limited to fans, but extends to your entire range of products!

Thus, it is ideal to minimise your fan warranty failures rate to less than 1%, to make the maximum benefit out of your warranty policy.

How Reducing warranty failures can help your business?

Fan manufacturers offer warranties on their products to give assurance to the customers that their fans are reliable and worth every penny they spend on them. It clearly acts as a competitive differentiator.

Moreover, the after-sales assurance in the form of a warranty enhances customer experience and adds brand value. It helps to gain more market share and increase brand perception. Again, if you sell a range of products apart from fans, a good performing product is more likely to influence sales of your other products in the range.

Whether you are manufacturing induction fans or BLDC fans, reducing the warranty failure rate is a sure shot way to further grow your customer satisfaction.

Causes of Higher Fan Warranty Failures and Ways to Reduce them

A closer look at the fan models with failed warranties gives insight into the possible causes of high warranty failures.  It can be attributed to –

Cause	Impact	Solutions
Issues in the fan manufacturing process	High warranty claims for fan models manufactured in a certain facility alone	1.      Implement better quality control processes in that facility.
Consumer Behaviour	Warranty failures caused by specific consumer behaviour. Say using input from a particular inverter brand/generator or frequent power fluctuations.	1.      Try simulating the consumer behaviour in the factory to find the cause of warranty failure and improve the product quality. 2.      If not solvable, add that as a clause in the warranty policy, making such situations ineligible for a warranty claim.
Supplier Issues	Faulty / defective / substandard components causing warranty failure	1.      Identify the failing component and talk to the supplier regarding the issue to improve the quality. 2.      Switch to a component supplier who follows thorough quality checks in the manufacturing process.

 

This article will focus on ways to reduce supplier issues that can cause fan warranty failures.

In a fan, the motor is the part that is usually covered under the warranty policy. And the winding wire is the most critical component in a motor. Thus, switching to good quality winding wire supplier for fan motors can reduce the fan warranty failure rate significantly.

Impact of Poor Quality Copper Winding Wires on Fan Warranty Failures

Usually, the warranty period for a fan model is for 2-5 years. The reasons for motor failure within the warranty period can be attributed to the quality of the copper winding wire used. Let us see how –

Uneven Magnetic Field –

If the winding wire used in a motor doesn’t meet the desired specifications for the fan design, it fails to produce and sustain the required magnetic field. It could hamper the efficiency of the motor leading to warranty failure.

Meeting the prescribed thermal, electrical and mechanical specifications of winding wire boils down to using pure conductor and insulation materials. Opting for a winding wire manufacturer using virgin copper and high-quality enamel coating as raw materials helps in this regard. In addition to using the latest technology, inline testing equipment and strict process controls are key factors that the fan winding wire manufacturer should have.

Fluctuating Power –

The fan motor is built to work at and withstand a certain amount of voltage. The thickness and uniformity of insulation or enamel in the motor winding determine the voltage fluctuations a motor can handle. A uniform enamel coating offers good breakdown voltage for the fan motor, saving it from failures due to power fluctuation.

The uniformity of enamel coating can be measured by testing the concentricity of the winding wire. At Geekay, we do routine concentricity testing and inline diameter and pinhole inspection as part of quality control to guarantee consistency in insulation.

Coil Failure –

The presence of pinholes or breakages in insulation in the winding wires can result in short circuits. This can attribute to motor failure over a period of time. A winding wire supplier who follows rigorous pinhole testing ensures negligible defects in the enamel coating.

Here is a video that shows the various testing processes conducted on enamelled winding wires to guarantee quality.

 

 

Using GK Winding Wires increases the lifespan of your motor as well as improves its efficiency. These strengthen your warranty policy and helps you get higher star rating.

Best Quality Copper Winding Wire Supplier for Fans – Geekay

GK Winding is a manufacturer and supplier of Enamelled Copper winding wires for various industries for more than 4 decades. At Geekay, winding wires for fans made using virgin copper or aluminium and high-quality insulation materials pass through a lot of quality testing processes. All these will enable you to make the best use of warranty policy to gain and maintain a strong foothold in the electrical appliances market.

Check out our portfolio of enamelled winding wires for fan motors.