Simulated workplaceCAQA Nexus Automotive Manufacturing is a fictional business created by CAQA for training and assessment. It is not a real company and no person, client or record here is real.About this simulation
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Simulated workplace
Scenario · Body Build and Fit-out

Diagnose, repair and test the trailer and body lighting circuit

You are an auto electrical technical operator on the fit-out line.

Intermediate3 to 4 hours7 tasks
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The situation

What has happened

Two marker light faults have appeared in a week. Non-conformance NCR-26-090 records an intermittent side marker circuit on pantech WO-26-0415, traced to a chafed loom behind the rear pillar. NCR-26-094 is a warranty return on flat top trailer WO-26-0409, delivered last week, where the fault was a loose earth stud. The Body Build and Fit-out Manager wants the pantech circuit diagnosed and repaired, the whole lighting installation tested against the heavy vehicle lighting requirements, both non-conformance records updated and an opinion on whether the loom routing work instruction needs to change. The customer quality audit in October will look at repeat non-conformances.

Your brief. Diagnose and repair the intermittent circuit, install and test the lighting to the applicable heavy vehicle standards, record the results, update both non-conformances with root causes and recommend a change to the work instruction if the evidence supports it.
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Tasks

Deliverables

  • Diagnostic plan and fault finding record
  • Lighting compliance check against the policy
  • Circuit test record on the work order
  • Updated non-conformance records with root causes
  • Recommendation on the work instruction

Documents to use

Systems to use

Non-Conformance Register

Records every product, material or process non-conformance found at stage gates, in the field or at supplier receival, with disposition and corrective action status.

Work Orders and Build Tracker

Tracks every body, trailer and bus build from planned release through fabrication, assembly, fit-out, paint and final inspection to delivery.

Plant Maintenance and Calibration Requests

Logs breakdown, preventive service, calibration and inspection requests for cranes, machines, welding equipment, booths and measuring equipment.

For trainers and assessors

Units of competency

Current on training.gov.au for the Automotive Manufacturing as at 10 September 2026.

AUMGTR001Install and replace vehicle electrical units and assemblies
AUMGTR003Test, modify and repair vehicle electrical circuits and systems
AUMGLM011Apply heavy vehicle standards
AUMGQA001Apply workplace technical quality standards
AUMGTM013Install or replace mechanical units and assemblies

Qualifications

AUM30226Certificate III in Automotive Manufacturing Technical Operations - Bus, Truck and Trailer
Assessor notes

What to look for

Evidence guide

The diagnostic plan must be systematic, moving from symptom to circuit to component with test points. Root causes must distinguish the chafed loom from the loose earth and identify the routing and securing gaps behind them. The lighting check must reference the applicable requirements for the body type. Look for use of calibrated test equipment and a recommendation supported by evidence rather than assumption.

The student's evidence summary lists every record they created or changed in the systems named above, their notes and the tasks they ticked. Verify it against the deliverables and your own assessment tool.