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 · Fabrication and Welding

Weld replacement trailer cross members with gas metal arc welding

You are a welder in the trailer frame bay.

Intermediate3 to 4 hours8 tasks
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The situation

What has happened

Non-conformance NCR-26-087 recorded porosity in the fillet welds on three cross members of drop deck trailer WO-26-0420. The cause was low shielding gas flow at bay 4, which maintenance has now repaired. The Leading Hand Welder has asked you to weld the replacement cross members to the welding procedure specification and present them to the fabrication gate so the trailer can move to final inspection and meet its delivery date of 18 September. The shop has just had an arc flash injury and the safety committee is watching screen and extraction discipline. Your welder qualification for gas metal arc welding in the required position is current in the training records.

Your brief. Set up the bay and the machine to the welding procedure specification, weld the cross members to the drawing, inspect the welds, record the work on the work order and update the non-conformance register when the rework is verified at the gate.
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Tasks

Deliverables

  • Weld symbol and procedure identification
  • Completed bay set up checklist
  • Machine parameter and gas flow record
  • Updated work order and non-conformance register entries
  • Incident and Hazard Report Form

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.

For trainers and assessors

Units of competency

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

AUMGTW005Perform gas metal arc welding
AUMGTW001Perform basic welding, thermal cutting, heating and gouging
AUMGTW002Perform mechanical cutting
AUMGQA001Apply workplace technical quality standards
AUMASA011Apply safe work practices in the automotive manufacturing environment

Qualifications

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

What to look for

Evidence guide

Weld symbols must be read correctly and the parameters must come from the specification, not memory. The student must link the gas flow check to the original defect cause. Where practical welding is observed, check fit up, sequence, weld profile and the absence of porosity and undercut. Records on the work order and the non-conformance register must be complete and traceable to the welder.

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.