Case Study

Investigation closures became predictable across automated food plants

A large food processing & FMCG manufacturer replaced ad-hoc investigations, manual audit tracking, and fragmented training records with structured RCA workflows, action automation, and cross-plant dashboards.

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Multi-plant
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Audit-heavy compliance
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6 min read
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Client Highlights

Check Icon Modules: Incident Investigation, Audit Management, Action Tracker
Check Icon Use Case: Structured RCA + audit-to-action automation across plants
Check Icon Outcome: Better investigation closure quality + fewer repeat + faster audit closure

Executive Summary

The Problem

  • Investigations lacked structured root cause workflows
  • Training tracking was manual and fragmented
  • External audit findings were tracked manually

What Changed

  • Digital incident investigations with structured RCA
  • Digital audits with automatic action creation from audit
  • Training dashboards with manual + bulk upload capability

What Improved

  • 55% improvement in investigation closure quality scores
  • 42% reduction in repeat minor incidents
  • 60% reduction in manual audit action tracking effort

The Challenge

1
Repeat incidents: Investigations didn’t force a clean RCA path, so the same patterns resurfaced.
2
Closure uncertainty: Evidence quality varied by plant and investigator, leading to inconsistent closure.
3
Audit friction: External audit findings needed manual tracking and action creation.
4
Training proof gaps: Compliance visibility was split across HR and plants, with no single truth.

Context & Constraints

Number of Sites Multiple automated facilities
Contractor Intensity High
SOP Alignment Strict Requirement
Offline Mode Enabled for low-signal areas

What We Implemented

Deploying a standardized, integrated safety environment across all active operational sites.

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Incident Investigations (RCA)

Configured for: Structured investigations that prevent repeat incidents.

Key Workflow Controls

  • Check Icon Guided RCA flow (Why-Why) with required fields
  • Check Icon Mandatory evidence attachments for closure
  • Check Icon Root cause + corrective/preventive action linking

Audit Proof Captured

  • Audit Proof Icon Full investigation timeline + ownership
  • Audit Proof Icon Evidence stored inside the record
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Audits + Training Compliance

Configured for: Audit findings → actions → closure, plus training visibility across plants.

Key Workflow Controls

  • Check Icon Digital audits with automatic action creation from findings
  • Check Icon Action ownership + due dates + escalation (overdue control)
  • Check Icon Training compliance dashboards (manual + bulk upload)

Audit Proof Captured

  • Audit Proof Icon Audit-to-action trail with timestamps
  • Audit Proof Icon Closure evidence linked to the original finding

Workflow at a Glance

1

Trigger

Incident is logged and routed into a structured investigation workflow.

2

Review

EHS assigns investigators and validates severity and required evidence.

3

Execution

Investigation runs through RCA (Why-Why), with evidence required at each stage.

4

Closure

CAPA is assigned, tracked, and validated before the case can close.

5

Visibility

CAPA is assigned, tracked, and validated before the case can close.

Field capture view UI

RCA investigation view with mandatory evidence gates

Corporate dashboard view UI

Corporate view: repeat themes + audit actions + training compliance

Measured Outcomes

Measured Outcomes Icon

Better investigations

55% improvement in investigation closure quality scores

What Enabled It Structured RCA + mandatory evidence closure
Measured Outcomes Icon

Fewer repeats

42% reduction in repeat minor incidents

What Enabled It RCA quality + linked CAPA discipline
Measured Outcomes Icon

Less audit admin

60% reduction in manual audit action tracking effort

What Enabled It Auto action creation + central tracking
Measured Outcomes Icon

Faster closure

47% faster audit action closure turnaround time

What Enabled It Ownership + deadlines + escalations
Measured Outcomes Features Icon Role-Based Access Control
Measured Outcomes Features Icon Immutable Audit Trail
Measured Outcomes Features Icon PDF/Excel Exports Available
Measured Outcomes Features Icon Offline Field Capture

Ready to standardise investigations and audits?

Download the one-pager summary, or request a security brief for your IT review.

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