A mechatronic training and simulation system and method of detecting and resolving complex control system errors in automation-driven process that replicates a scaled factory. The system provides student work stations that allow students to monitor, analyze and repair an automation-driven process. The automation-driven process includes at least one scaled model factory station simulator such as: a robot station, a warehouse station, a furnace processing station, and error checking color sorting station. A problem interjecting device to introduce errors to the automation-driven process through discrete I/O interfacing to interrupt process flow by breaking inputs and breaking outputs. Students at the student work stations, independently or concurrently, analyze and repair interruptions in automation-driven process through use of interface software and electrical measurement instruments. Students learn theoretical and practical hands on technical knowledge for debugging and troubleshooting programmable logic con
