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
AUMCAQA NexusSimulated workplace
Simulated workplace
Scenario · Production Planning and Support

Lead a productivity improvement project on the fit-out line

You are a leading hand seconded to lead the fit-out line improvement project.

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The situation

What has happened

Only 88 per cent of builds are leaving the fit-out line on schedule and rework hours per build have climbed to 2.1. The General Manager has asked the Production Planning and Support Manager to run an improvement project and you have been asked to lead the crew through it. Known issues include a back order on amber marker lights that has stopped work twice, a missing panel lifter that contributed to a hand injury, repeat marker light faults, and a second shift starting on 21 September that will double the number of people using the same tools and stores. The customer quality audit on 14 October will look at how the business manages repeat problems. The proposal and trial plan are due in two weeks.

Your brief. Gather and analyse the data from the work orders and non-conformance register, involve the crew in identifying causes, propose improvements with measurable benefits, plan a trial and prepare the proposal and a customer facing explanation of how delivery reliability will improve.
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Tasks

Deliverables

  • Data summary of fit-out delays, rework and stock outs
  • Crew session record and cause analysis
  • Completed Continuous Improvement Proposal
  • Pre-second shift equipment and stock action list
  • Leadership plan and customer service note

Documents to use

Systems to use

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.

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.

Materials and Components Stock

Stores register of steel, sheet, fasteners, hydraulic, electrical and paint stock with quantities on hand, reorder points and supplier.

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.

AUMAMM001Influence and lead work groups in an automotive manufacturing workplace
AUMGMA001Participate in workplace productivity improvement processes
AUMFQM001Apply continuous improvement in automotive manufacturing
AUMATK013Monitor and maintain automotive equipment
AUMGCA001Provide customer service

Qualifications

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

What to look for

Evidence guide

The data summary must use the seed records and be numerically correct. Cause analysis must reach system causes such as reorder points, equipment availability and work instruction gaps rather than blaming individuals. The proposal must have a measurable benefit and a realistic trial. The customer note must be honest about what is a trial and what is confirmed. Look for evidence of genuine crew involvement.

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.