Explore TPC's blog, where you'll discover the latest solutions, bold ideas, and quick wins for making training accessible to every maintenance technician. Get tips, insights, and dive into fresh suggestions for improving maintenance operations — and help your teams work smarter, grow their confidence, and stay ahead of the competition.
January 23, 2026
In warehousing and distribution, cross-training fails without fundamentals. Many organizations in this space approach widespread cross-training in a way that lacks structure. This can improve initial responsiveness, but without a keen understanding of root cause analysis, organizations lose out ...
December 17, 2025
Water pump systems don’t last forever and eventually they need to be replaced with newer, more efficient models.
September 16, 2025
According to the National Institute of Standards and Technology (NIST), reshoring will primarily benefit smaller, more nimble manufacturers as they are able to leverage localized supply chains for greater flexibility and faster turn times.
July 24, 2025
Reaching Generations Z & Alpha is how you safeguard your maintenance workforce. Regardless of your current maintenance team’s structure, their experience levels, and their commitment to your company.
June 17, 2025
If you’re experiencing budget cuts or belt-tightening at work, maximizing your training budget may not feel intuitive. However, it is an impactful step to take in securing your maintenance team’s skills and reducing the risk of expensive accidents and citations.
April 3, 2025
These industries have a massive impact on our standards of living in the U.S., and if the industrial sector grinds to a halt, it could impact more than prices at the store or pump.
December 10, 2024
Based on Plant Services’ special research report and the 2024 market survey of approximately 200 manufacturers, respondents providing technical training were allowed to select multiple reasons for offering their maintenance team members training.
September 26, 2024
Respondents were asked to choose their top 3 skills. In fact, only about half included core maintenance skills as a top pick. The results were as follows.
September 6, 2024
According to a survey we completed in Q1 2024 with Plant Services, it isn’t just the managers who are administering training. A whopping 13% of critical maintenance technicians, such as skilled trades and others who work to keep your equipment up and running
August 8, 2024
Predictive Maintenance is a powerful strategy, but it might not be practical for all devices in your facility. For example, if a machine isn’t critical – short periods of downtime are manageable – or repairs can’t be predicted, then it might not be worth maintaining with a predictive model.
August 8, 2024
major shift in the workforce is expected in the next decade, and many employers expect to see a dramatic increase in retirement of the workers who maintain and repair mission-critical machinery.
February 28, 2024
According to Article 120 of NFPA 70E® Standard for Electrical Safety in the Workplace, establishing an electrically safe work condition is a necessary, effective, and multi-step process that encompasses a much higher level of safety than a simple lock & tag.
January 30, 2024
Electrical work is dangerous. Understanding the risks and protecting your workers is the best way to ensure they enjoy long careers with few injuries.
December 28, 2023
With aggressive growth in the sector over the past decade, industrial automation has been proven to improve facility safety and productivity and drive the demand for skilled tradespeople and the technician workforce.
November 29, 2023
Emergency incidents are unpredictable. They can occur at any time and on any job site. Whether natural or man-made, emergencies can threaten workers and the public, disrupt operations, or cause physical damage to an environment.
September 8, 2023
Leaving the electrical maintenance to qualified electrical workers (QEW) or licensed electricians is a must; with properly trained workers handling the preventive maintenance, troubleshooting, and repairs to electrical systems, the chance of electrical faults, downtime, and accidents will be reduced
June 6, 2023
When machines aren’t performing properly, your team’s morale and safety might suffer. Downtime is costly, but incurring penalties due to unsafe working conditions makes it much more expensive.
April 25, 2023
Statistics show that 1 in 4 businesses won’t reopen following an emergency. They also demonstrate that the frequency and significance of man-made and natural disasters is increasing.
April 3, 2023
With simulations, your team will explore a virtual environment where they can practice troubleshooting common faults, using the tools and components they’re already familiar with.
February 17, 2023
A premier nutrition, agricultural origination, and food processing company headquartered in Chicago, Illinois, with 800+ facilities, 50+ innovation centers, and 38,000 employees, provides their customers with solutions to nutritional challenges.
February 2, 2023
The challenge is that Gen Z, the latest generation to start to join the workforce, learns with a deep foundation in technology. Teaching these students requires different strategies than previous generations just to keep their attention.
November 10, 2022
Work-related injuries or disorders affecting muscles, tendons, nerves, cartilage, joints, or spinal discs are known as musculoskeletal disorders (MSDs).
September 29, 2022
Long before Chambers ever stepped foot in front of a class of students, he was imagining how he would teach material – in a totally different way than his high school teachers did.
August 31, 2022
Training needs assessments are based on roles and responsibilities, job hazards, controls, work processes, personal protective equipment (PPE), and training requirements. By reviewing these areas, you can identify the knowledge needed to recognize hazards and prevent injuries.
July 25, 2022
Throughout Bob Clukey’s tenure at TPC Training, he has had the opportunity to teach courses at the Pentagon, Camp David, and many manufacturing facilities including Tesla and Amazon.
March 22, 2022
It’s quite rare to find a person with technical mastery who also is great at teaching, though, and in most facilities, on-the-job training comes with these pitfalls
February 9, 2022
Gregg Sutton always knew he wanted to teach. Early in his career, he was given an opportunity to teach adult education courses at a vocational technology school, but after struggling to find the right full-time teaching role, he spent over 20 years using his practical skills instead.
January 25, 2022
Training courses allow workers to learn the best practices for their jobs, whether it be safety precautions, troubleshooting methods, or simply tricks of the trade. When multiple workers participate in training as a team, they can rally around the best practices learned in their training courses.
December 9, 2021
Manufacturing downtime can have a ripple effect on any company. Inventory declines, supply chains are slowed, employees are left without work and customers are disappointed.
December 6, 2021
Industry researchers have found that the average downtime episode lasts 1.5 to 4 hours and costs between $30,000 and $50,000 while production crews sit idle waiting for machines to come back online, and then earn overtime while the plant plays catch up to make its quotas.
October 8, 2021
This post is part of a series designed to help our customers get the most out of the Electrical Troubleshooting Skills Training System™.
October 8, 2021
Today we’ll be looking at how to calculate the true cost of facilities maintenance. It’s not exactly news that factory downtime costs manufacturers.
October 8, 2021
For the past few Troubleshooting Thursday posts, we have been discussing TPC’s systematic troubleshooting methodology to build a solid foundation for learning troubleshooting. It is now time to start looking into the multimeter and other tools used to execute this approach.
October 8, 2021
A short circuit occurs when an accidental connection is created when a wire carrying current comes in contact with a neutral wire or the ground in a circuit. d
October 8, 2021
Electrical accidents are common, if not unavoidable, in the manufacturing environment. They occur for several reasons—whether it concerns the management, equipment, or employees.
October 8, 2021
Open circuit faults are most common and are relatively easy to troubleshoot. Typically, this type of fault can be identified quickly as some part of the circuit will not be operating since it is not receiving the voltage required for correct operation.
June 18, 2021
According to the Department of Energy, the number of commercial buildings and industrial facilities in the United States is nearly 6 million.
May 25, 2021
With a diminishing pool of skilled workers in the industrial labor market, companies return to apprenticeship programs to grow their own workforce. In recent history, apprenticeships have been a widely overlooked method that places valuable and loyal workers on shop floors.
May 21, 2021
Advances in the design and quality of electrical components have made it possible for electrical systems to run for years without noticeable problems.
May 11, 2021
If pumps were ideal, the horsepower entering the pump would equal the horsepower exiting the pump, producing 100 percent efficiency. Unfortunately, friction, leakage, and other energy losses will always mean mechanical horsepower input will be higher than water horsepower output.
April 27, 2021
All jobs come with some safety hazards, from the lack of an ergonomic keyboard in an office setting to the risk of arc flash when operating heavy electronic equipment.
April 22, 2021
According to Electrical Safety Foundation International, the US workforce experienced 1,900 nonfatal electrical injuries and 166 fatalities in 2019. Safety for electricians and other employees is of great concern, given the often severe nature of electrical accidents.
April 21, 2021
Electricity-related injures occur to more than 4,000 workers every day in the United States and frequently these injuries can result in death.
April 7, 2021
Chilled water systems remove heat from buildings by transferring heat from the air into cold water forced through piping. The water circulates through chilled water loops, absorbing heat and returning the heated water to the chiller where refrigerant rechills the water.
April 6, 2021
Electricity is a form of energy, which can be generated by several methods, including hydroelectric dams, coal-fired steam plants, and chemical batteries. No matter how it is created, electricity then flows through conducting circuits, where it powers pumps, motors, mixers, and more.
April 5, 2021
Confusion sometimes arises when discussing OSHA recordable vs reportable events, in part because not all recordable events are reportable. Here’s a brief explanation of OSHA recordkeeping requirements, with examples of recordable vs reportable events.
March 31, 2021
Find the BEST list of safety slogans right here! We have 500+ slogans for you to choose from. Whether you're looking for a funny slogan or something industry-specific, you're sure to find something on this list.
March 23, 2021
Companies that value well-trained employees often have ongoing training programs in place. Ongoing does not mean continuous, so how often should you provide ongoing training to employees?
March 8, 2021
Training your employees provides multiple advantages. Regular training helps ensure your staff are applying the latest information and best practices to their work, improving your overall productivity and compliance rates.
March 1, 2021
Clothing, face shields, gloves, and other gear must provide the level of protection needed for a given hazardous situation.
February 12, 2021
As you might expect, the more effort you put into maintaining your boiler, the longer you can expect it to function. Here’s how to extend boiler life.
February 10, 2021
Installing or upgrading HVAC for historic buildings is a complicated—and sometimes nerve-wracking—process. As the HVAC installer, you have two responsibilities that can sometimes clash.
February 10, 2021
Deferred HVAC maintenance is a new term for that old adage, “if it ain’t broke, don’t fix it.” On the surface it makes sense—if the HVAC system is running, why expend the resources associated with preventative maintenance?
February 5, 2021
PLCs continuously monitor information from analog or digital input devices. The PLC makes decisions based on the input received, which are delivered to monitored equipment through the PLC’s output interface.
January 29, 2021
Choosing the right types of pump requires an understanding of the classifications of pumps: the right pump for one situation is entirely wrong for other pump applications.
January 25, 2021
An understanding of electrical wiring improves the efficiency and safety of any facility’s employees, especially for non-electricians who perform basic maintenance on electrical equipment.
January 20, 2021
Simulation training immerses students in a virtual training environment that replicates real-world equipment and workplace processes. Some training goes so far as to duplicate the sounds of the workplace for added realism.
January 15, 2021
knowing how to do schematic diagrams is an important skill in such cases, as accurate and accessible electrical drawings are required for safety compliance.
January 8, 2021
Knowing how to read a blueprint is a valuable skill for anyone who works in construction, maintenance, or facilities management. Accurate blueprint reading helps you identify the location of important building elements during renovations, rebuilding, or work on electrical and HVAC systems.
January 5, 2021
While many aspects of industrial training can be taught enmass through online or offsite seminars, some types of information and skills are better taught in small onsite groups.
January 4, 2021
Delivering timely, accurate training to employees is a major challenge for your facilities managers department, whether said training is required to onboard new hires, provide updated information to experienced employees, or ensure contract workers meet safety compliance requirements.
December 3, 2020
The ubiquitous nature of electricity sometimes causes people to neglect electrical safety hazards. People are so used to instant, safe access to electricity they forget just how powerful electrical energy is.
November 10, 2020
Learning how to read an electrical schematic drawing is an important skill for maintenance workers and managers even if they aren’t licensed electricians. Understanding schematic drawings helps identify faulty components, troubleshoot systems, and improve safety.
November 9, 2020
Factory downtime costs are the bane of the manufacturing industry, with facilities losing anywhere from five to twenty percent of productivity to downtime every month.
October 30, 2020
Tyson Foods, Inc., with a corporate base in Springdale, Arkansas, is comprised of 110 production facilities with approximately 120,000 employees throughout the US.
October 8, 2020
A portable generator is used to produce electricity when temporary or remote power is required. Often used on construction sites or to power facilities during power outages or disasters, portable generators are powered by engines, and must be used with care to avoid injury and fire.
October 1, 2020
Due to the significant risk of fatalities and life-changing injuries, OSHA has strict requirements for electrical standards, requiring employers to prove they took reasonable precautions to prevent injury.
September 16, 2020
Simulation training offers opportunities to practice complex and sensitive processes in a safe, virtual environment. But what is simulation training, and do simulation training methods have a place in your workforce training program?
September 16, 2020
In August of 2020, TPC Training acquired Simutech Multimedia, an industry leader in the world of simulation training systems.
June 11, 2020
You and your company face work situations and challenges that have not been a factor since the 1918 Spanish Flu outbreak. We are living in a “new normal,” and it’s likely how we live and work has changed forever.
June 9, 2020
Live online training combines the convenience of online training with the face-to-face engagement of the traditional classroom.
April 17, 2020
Workforce management provides a company with the tools needed to improve efficiency and overcome employee-related challenges, including those associated with safety, productivity, attendance, payroll, and regulatory compliance.
April 16, 2020
Learn how TPC’s partnership with one of the largest school districts in Illinois helped them streamline and build upon their ongoing training program creating efficiencies.
April 14, 2020
Online training courses have become more popular as organizations implement new safety guidelines and require more flexibility to improve technical skills knowledge among the workforce. Employees in need of training may work at remote facilities or work different shifts.
April 14, 2020
With so many online training courses available, it can be difficult to choose which type of remote training your employees need. The most important training courses for one industry may not be needed in another (what office worker needs to understand lockout/tagout procedures?).
April 14, 2020
Online training benefits both employees and employers, but only when two criteria are met. Online training courses must keep employees motivated, and training results must be tracked in a way that allows the employer easy access to testing data.
March 18, 2020
Off-site classroom instruction typically comes with significant add-on costs. Travel to and from the instruction venue, food, accommodation for employees during instruction, and the temporary absence of employees can raise training expenses while lowering productivity.
March 17, 2020
Despite all the advances in online training, in-person training remains the most efficient way of teaching employees the skills they need to excel in their job. Off-site in-person training is expensive, however.
October 21, 2019
Automating hazardous operations can greatly improve workplace safety, but the relationship between automation and safety goes far beyond distancing employees from dangerous tasks.
October 14, 2019
OSHA reporting and incident tracking is a vital part of health and safety management. An inaccurate or missed OSHA report can have serious repercussions on a company.
October 4, 2019
Complying with local, state, and national regulations requires a paper trail--it doesn't matter if you’re in compliance if you can’t prove it.
May 23, 2019
Asbestos is an umbrella term describing six natural fibrous materials, all of which are mined. For years, asbestos was praised as a miracle material due to its strength, flexibility, electrical resistance, and ability to withstand chemical and thermal degradation.
April 16, 2019
Lock out / tag out, also known as energy control procedure, is a set of essential safety steps required before working on potentially energized machinery.
March 1, 2019
We interviewed 18 top legal experts in order to provide you with a list of critical information you should be aware of in the event you receive an OSHA citation.
February 6, 2019
Arc flash describes a dangerous event which occurs when electric current leaves its intended path and arcs through the air until making contact with another conductor or the ground.
January 17, 2019
An arc flash is a potentially destructive workplace accident, capable of causing severe injury and equipment damage in the space of a few seconds.
January 2, 2019
Electricity is a powerful force, and it’s no surprise that electrical safety usually comes up in conversation when work safety topics are discussed.
September 15, 2018
Corrective and preventive maintenance are often classified by levels of complexity, with each level indicating the need for more specialized training to successfully complete procedures, diagnostics, and repairs.
August 29, 2018
Employee engagement and performance are inseparable. Without high employee engagement, performance and productivity plummet. Employees with low engagement have lower morale and are more likely to seek—and find—new work.
August 27, 2018
In 1885, German psychologist Herman Ebbinghaus created a mathematical model that demonstrates how quickly people forget new information. Called the “forgetting curve,” Ebbinghaus’s model indicates people lose roughly seventy percent of what they learn within twenty-four hours.
August 22, 2018
Proper motor pump alignment helps ensure your equipment has longer life spans while requiring fewer repairs and costly downtime. Here we’ll explain what motor/pump alignment is, why it’s so important, and why your maintenance staff need alignment training.
August 8, 2018
Roller bearings are one of the sturdiest precision components in industrial motors and other applications, with less than one percent not completing their expected lifecycle.
August 1, 2018
Commercial HVAC systems make up a large portion of a building’s energy demands and need regular maintenance to operate at peak efficiency. Even with the best care, your HVAC system can develop problems that impact air and temperature quality, increase energy consumption, or damage system components.
July 10, 2018
Every facility, whether domestic or abroad, runs on information. But too often the information that a workforce needs to operate and maintain the equipment in their facilities is severely outdated, missing, or difficult to utilize in the field.
June 21, 2018
Measuring training effectiveness should be part of any training program. What happens in the weeks and months after training reveals whether training has had any lasting changes on your business.
June 16, 2018
Signs your employees need training can be subtle, especially if your corporate culture has grown accustomed to working around gaps in skill sets and knowledge.
April 18, 2018
Variable Frequency Drives (VFDs), also referred to as Adjustable Speed Drives, are prominent in today’s workplace. They are used in elevator, water pump, high-volume air compressor applications and material-handling systems wherever speed and torque characteristics of AC motors are regulated.
February 5, 2018
The National Electric Code defines industrial electrical control panels as an enclosure or open panel containing two or more power circuit components, control circuit components, or a combination of the two.
January 3, 2018
When times get tight and the economy flounders, businesses look to cut costs. Typically, one of the first areas to feel the bite of cutbacks is employee training.
November 15, 2017
Grounding and bonding requirements are designed to protect staff and equipment from undesired surges and buildup of electrical current.
October 24, 2017
Arc flash is a serious industrial accident where electrical current leaves its intended pathway and travels through the air. Between five to ten arc flash explosions occur in the USA every day, with 2,000 people a year treated in burn centers for arc-related injuries.
October 11, 2017
Creating and implementing an effective maintenance plan takes time and effort, but the end result is well worth the effort. Your goal is to reach a point where preventative maintenance accounts for at least sixty percent of all maintenance tasks, and emergency maintenance is an uncommon occurrence.
September 27, 2017
HVAC technicians work with often-dangerous acids and refrigerants, which can harm both people and the environment. To ensure proper training, the EPA requires all HVAC technicians have proper certifications.
September 4, 2017
Troubleshooting equipment—especially electrical equipment—has a certain mystique to it. Watching an experienced employee troubleshoot a piece of familiar equipment can make it seem as if the process is instinctive.
May 20, 2017
A commercial energy audit offers a chance to determine your HVAC system’s energy needs and identify possible areas of concern by examining energy use and performing a component-by-component examination of system health.
May 1, 2017
Electric motors operating on alternating current often run at unnecessary speeds, waste power, and heat up due to excessive harmonics. Variable frequency drives resolve these issues by controlling AC motor speed and torque by varying the frequency (hertz) and voltage delivered to the motor.
March 16, 2017
Effective skills training is measured through its outcomes and whether defined workforce goals are accomplished. Characteristics that make up ideal training program design include intensive training on real work applications and return workers back to their jobs quickly are agreed upon.
March 14, 2017
TPC Training is the leader in maintenance, repair, and operator training.
December 13, 2016
If your building needs an electrical maintenance team you may well decide to recruit members of your existing team and train them for the task at hand. In most cases, they’ll start with a basic electrical course.
November 14, 2016
When it comes to maintenance strategies, mechanical assets tend to receive more care than electrical control and distribution systems. Electrical systems can run for years without problems, making it tempting to focus on systems where wear and tear produce more frequent issues.
November 12, 2016
If you work with air conditioners or refrigerants, then you need your EPA 608 certification. Any person who opens a system or container holding a controlled refrigerant is required by the Federal Environmental Protection Agency to hold either a Type I, II, III, or Universal EPA 608 certification.
November 9, 2016
When the economy worsens and a company’s bottom line suffers, facilities managers often see their budgets decimated. As a result, Staff may be laid off, inventory reduced, and important facilities management training courses delayed or cancelled.
October 11, 2016
When a building resident reports foul odors from air conditioning, facility managers have a wide range of potential culprits to consider. Often the odor itself provides a clue to the root cause of the problem and may indicate anything from a mild mold problem to a dangerous buildup of toxic fumes.
September 12, 2016
An arc flash event is a dangerous situation occurring when electricity travels through the air to make contact with a conductor or the ground. Arc flashes release exceptionally high heat energy, pressure waves, blinding light, soundwaves, and toxic fumes.
August 23, 2016
Improving your company’s preventive maintenance (PM) program can feel overwhelming. PM processes often develop organically as new machinery and equipment comes into play, old equipment is phased out, and new reliability strategies become available.
July 19, 2016
Located on the outside of the building, an air conditioner’s condenser is exposed to the elements and vulnerable to damage. Here’s how to identify and prevent problems with your condenser before they become serious.
June 27, 2016
Regularly scheduled servicing and maintenance of your switchgear can greatly increase its lifespan, but eventually, you’ll find yourself wondering if simply replacing the system isn’t a better investment.
April 15, 2016
Electric fires rank among the top five causes of commercial building fires according to the National Fire Protection Association. In many cases, the source of an electric fire can be traced to electric overloads.
April 5, 2016
With severe weather on the rise, so too are power outages.
March 1, 2016
Electrical arc flash is a dangerous hazard for anyone working on or near energized conductors and equipment. A proper understanding of the potential hazards is a big part of your overall electrical training regimen.
February 6, 2016
An arc flash is likely to be catastrophic to any electrical worker unlucky enough to experience one.
May 25, 2015
Did you know that OSHA and NFPA require documented in-person or classroom training for electrical workers? We find that many of our customers are unaware of these requirements; understanding them can make your facility safer and reduce employer liability.
May 5, 2015
By bringing together multiple formats, TPC can issue the most effective method to address workforce training and current skills gaps.
February 26, 2015
Workforce attrition studies have shown that successful employee training programs produce many benefits to companies and organizations including:
January 23, 2015
Organizing an ongoing skills training program is a smart decision for any company looking to help their employees meet business goals.