This study presents a data-driven approach for strengthening aviation safety by integrating human factors assessment with modern predictive modeling techniques. The work focuses on understanding how human performance, operational conditions, and system-level interactions collectively influence safety risk, and how these interactions can be quantified to support improved design and decision-making. Unlike previous studies that address human factors or predictive modeling in isolation, this research offers a unified framework that links causal human factors indicators with statistical modeling, feature extraction, and machine learning based risk estimation. The novelty of this work lies in the structured pipeline that transforms raw categorical and narrative human factors information into measurable predictors that can be analyzed using structural modeling and machine learning. The methodology includes data preparation, dimensionality reduction, latent pattern discovery, dependence modeling, model training, and interpretability analysis. The study demonstrates how this pipeline uncovers hidden relationships among operational errors, environmental influences, maintenance actions, design considerations, and crew behavior. The findings show that the integrated approach improves the accuracy and stability of risk prediction and highlights specific human factors patterns that consistently contribute to elevated risk levels. These insights support targeted mitigation strategies, inform design improvements, and help prioritize safety interventions. The work concludes that a combined human factors and predictive modeling framework enhances the ability of organizations to identify vulnerabilities earlier, allocate resources more effectively, and strengthen system resilience. This approach is adaptable to diverse aviation contexts and offers a practical path for transforming human factors data into actionable safety intelligence.