This is due to corrupt career outfits
You can try the following
1. Change the SIm into his work outfits manuelly before they have to leave
2. Edit the Career Outfit via the dresser. If the Sim has more than one, delete the extra. If he has just one, create a new one.
I'm having these problems, too. But I can't edit the Sim's outfit in the dresser. When I try to edit his career outfit, the game is forever stuck at the "Loading Create-A-Sim" screen. Also, when I select his career outfit manually, his career outfit becomes whatever he was previously wearing. I could make him go to work in his pajamas if I wanted to. Why haven't they fixed this yet?
