Precision and Partnership: How Engineering Dynamics Transformed Alignment Operations for a Client

In the world of opencast mining, precision isn’t just a preference – it’s a necessity. This is where Paul Whaling comes in. As part of Reid and Mitchell’s field service team, a company that has been maintaining and refurbishing high-value electrical rotating equipment since 1935, Paul knows that even the smallest misalignment can lead to big problems.

“Every shutdown costs money,” explains Paul, who has spent 14 years keeping some of Africa’s largest mining operations running. “When you’re aligning critical machinery, you need both accuracy and speed.” 

Until 2019, Paul’s team relied on equipment that, while perfectly functional, came with significant operational hurdles. Software updates required international shipping and costs approaching R100,000 per instance. Then, through a colleague’s recommendation, they discovered Engineering Dynamics (ED) and their Easy-Laser systems.

Today, armed with their Easy-Laser XT770, Paul’s team of four handles alignment jobs across various sites. Their work is crucial for Reid and Mitchell’s comprehensive service approach, which includes everything from engineering appraisals to maintenance service agreements. They’ve built up an extensive database of readings and measurements, allowing them to track changes over time and spot potential issues before they become problems. When a machine goes down, they can pull up its entire history, regardless of which team member did the previous measurements.

The local support from Engineering Dynamics has made a particular difference too. “Just last week, we borrowed a belt alignment tool,” Paul mentions. “Try getting that kind of service from an overseas supplier.” When his team needs help, they can call ED directly. Werner Bauer, who trained the entire field service team, often offers to analyse readings if someone’s unsure what they’re seeing. This knowledge transfer has proved invaluable. When one team member returned to alignment work after a seven-year hiatus, the intuitive system, thorough training and support enabled him to step back in seamlessly.

A recent project in Morocco perfectly illustrates the transformation further. Tasked with rebuilding a dragline – which was being converted from 60Hz to 50Hz – Paul’s team faced the challenge of coupling six generators in a precise train alignment. “We used to do alignments the old-school way,” Paul explains. “Feeler gauges, lots of time, lots of double-checking and struggles with the end units.” 

“In Morocco, we decided to run an experiment,” Paul says. “We did one train the old way, then used the Easy-Laser system for the rest. The results were nearly identical, but we completed the four train alignments in a day. The old method would have taken three or four days.”

The older technicians were sceptical at first – as experienced hands often are when faced with new methods. But the results spoke for themselves. Not a single unit showed vibration readings above 3mm/sec, impressive for refurbished equipment. The client was happy, headquarters was happy, and delivery dates were met with time to spare.

For Paul, it’s the practical things that matter most: software updates are free for life, calibrations happen locally (often same-day), and belt alignment capabilities come pre-loaded without extra licensing fees. “In our industry, there are only two companies that can do laser alignments,” Paul notes. “But when mines know you have both the equipment and experience to provide on-site reports, that makes a difference.”

As mining operations increasingly focus on efficiency and uptime, Reid & Mitchell’s field service team exemplifies how the right combination of technology and support can transform maintenance operations. “We’re not just maintaining equipment,” Paul concludes. “We’re building a knowledge base that helps us predict and prevent issues before they become problems. And we couldn’t have done it without Easy-Laser products and the Engineering Dynamics team!”