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Simulated workplace
Scenario · Safety, Quality and Compliance

Investigate a tyre changer near miss and run a toolbox talk

You are the acting WHS and Quality Coordinator.

Advanced3 to 4 hours8 tasks
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The situation

What has happened

At the Geelong tyre centre the bead breaker on the tyre changer activated while the operator's hand was near the blade. Nobody was hurt, but the guard was found bypassed with a cable tie. The event is logged as HZ-26-035 in the Incident and Hazard Register with the machine isolated and the investigation open. The WHS and Quality Coordinator is at another site all week and has asked you to lead the investigation, find the reasons the guard was bypassed, propose corrective actions that address the cause rather than blaming the operator, and prepare a toolbox talk for both sites. The Plant and Equipment Register shows the machine's inspection history, and the hierarchy of control in the WHS Policy applies to any control you recommend.

Your brief. Investigate the near miss using records and interviews, identify immediate and underlying causes, recommend corrective actions ranked by the hierarchy of control, update the register, and prepare and record a toolbox talk that consults workers on the findings.
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Tasks

Deliverables

  • Investigation report with causes and corrective actions
  • Updated Incident and Hazard Register entry
  • Completed toolbox talk record with attendance
  • Plant and Equipment Register review notes

Documents to use

Systems to use

Incident and Hazard Register

Records injuries, near misses, hazards, property damage and environmental spills with investigation findings and corrective actions.

Repair Orders

Tracks every customer and stock vehicle job from booking to invoice with concern, work lines, parts, labour, quotes and quality check.

For trainers and assessors

Units of competency

Current on training.gov.au for the Automotive Retail, Service and Repair Training Package as at 10 September 2026.

AURASA001Apply automotive workplace safety fundamentals
AURAQA003Maintain quality processes in an automotive workplace
AURAMA006Contribute to planning and implementing business improvement in an automotive workplace
AURAMA003Conduct information sessions in an automotive workplace

Qualifications

AUR40116Certificate IV in Automotive Management
AUR50126Diploma of Automotive Management
Assessor notes

What to look for

Evidence guide

The investigation must go beyond the operator's action to underlying causes such as production pressure, guard design or maintenance. Corrective actions should be ranked by the hierarchy of control and assigned owners and dates. The toolbox talk record must show consultation, questions raised and actions. Check the notifiable incident reasoning is sound.

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.