Data-Driven Corrective and Preventive Action (CAPA) Systems for Quality Assurance Optimization

Data-driven Corrective and Preventive Action (CAPA) systems are emerging as transformative tools for optimizing quality assurance and ensuring sustained food safety performance. This study investigates how digital CAPA frameworks leveraging predictive analytics, machine learning, and real-time data visualization can significantly reduce non-conformances, strengthen process efficiency, and reinforce continuous improvement in food manufacturing operations. Traditional CAPA systems, though essential for compliance, often rely on reactive measures that identify deviations post-occurrence, leading to delays, inefficiencies, and repetitive quality lapses. By contrast, data-driven CAPA models integrate advanced analytics with digital quality management platforms to enable proactive identification of potential risks, root cause analysis, and timely corrective actions before deviations escalate into regulatory non-compliance. The research explores the fusion of Internet of Things (IoT) sensors, enterprise data systems, and predictive algorithms that enable automatic capture, analysis, and correlation of quality events across production lines. Through trend recognition and anomaly detection, digital CAPA models provide actionable insights that facilitate continuous process optimization. These systems enhance traceability, promote evidence-based decision-making, and foster a culture of quality ownership throughout the organization. Moreover, the integration of predictive analytics supports early warning mechanisms that detect deviations in hygiene, temperature, and contamination thresholds key determinants of food safety. This study also examines the alignment of data-driven CAPA systems with Hazard Analysis and Critical Control Point (HACCP) principles and ISO 22000 requirements, demonstrating how harmonized frameworks improve audit readiness, documentation integrity, and regulatory compliance. Implementation case analyses reveal measurable reductions in recurrence of non-conformances, cycle times for corrective actions, and costs associated with product recalls and waste. Ultimately, the adoption of digital CAPA supported by predictive analytics enhances organizational agility, reduces operational risk, and accelerates the path toward a zero-defect culture in food manufacturing. By embedding intelligence, transparency, and traceability into quality management systems, data-driven CAPA models represent a critical evolution in modern food safety governance. The findings underscore their potential as a strategic enabler for continuous improvement, operational excellence, and regulatory resilience within global food supply chains.