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 · Paint and Finishing

Identify and rework paint faults on a curtainsider bulkhead

You are a vehicle painter in the paint shop.

Intermediate3 to 4 hours7 tasks
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The situation

What has happened

Curtainsider WO-26-0418 for Statewide Fleet Leasing failed the paint gate with two runs on the front bulkhead, recorded as NCR-26-089. The customer wants the vehicle on 9 October and it is one of three identical units that will be inspected during the customer quality audit. Booth 1 is being serviced because its airflow is dropping, so the rework must be done in booth 2. Last week a painter entered a booth during flash off without a respirator and reported chest tightness, so the supervisor is enforcing booth entry rules strictly. Your respirator fit test is current and the air supplied set is available.

Your brief. Identify the paint fault type and its cause, plan and carry out the rework to the procedure in booth 2 with the correct respiratory protection and booth checks, inspect and record the result on the work order and update the non-conformance record for re-inspection at the paint gate.
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Tasks

Deliverables

  • Booth and respiratory protection plan
  • Fault identification and cause analysis
  • Rework plan with mixing and film thickness records
  • Updated work order and non-conformance record
  • Waste record and hazard report

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.

Safety Incident and Hazard Register

The register of injuries, near misses, hazards, chemical exposures and property damage across the three sites, with investigation status and actions.

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.

AUMGTP001Finish and paint vehicle body and part surfaces
AUMGTP002Rework vehicle paint faults
AUMGTY001Paint vehicle chassis and panels
AUMASA011Apply safe work practices in the automotive manufacturing environment
AUMGTM008Bond and repair fibreglass components

Qualifications

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

What to look for

Evidence guide

The fault must be correctly identified as runs with plausible causes such as excessive film build, low viscosity, gun distance or insufficient flash off. The rework plan must follow the technical data sheet and the procedure, including pot life and flash off. Respiratory protection and booth entry rules must be correct. Records must be complete and the waste handled to the policy.

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.