Dynamic prediction of risk levels for manufacturing operations through leading risk indicators: dynamic risk fault tree method and system

A dynamic risk fault tree system for analyzing risk levels for manufacturing operations comprising:

• a server that receives automatically measured process data from a real-time data source and/or a historical archive data, source and long-term process data for a period preceding the measured process data, and an expression, previously uploaded by a user of the system, that is either true or false;
• a processor that analyzes values of parameters P and/or groups G of said parameters P of said measured process data at time interval T and compares the measured process data to the expression to determine whether the expression is true or false and based on whether the expression is true or false identifies operational risk and/or near-miss risk that would otherwise be unknown or concealed in parameters P, whereby said operational risk and/or near-miss risk is used for strategic corrective action;
• and
• a display that presents the expression on the dynamic risk fault tree as a node over a specified time period and wherein the node is displayed in one configuration when the expression is true and a different configuration when the expression is false;
• wherein said system continuously and autonomously, operates contemporaneous with said manufacturing operation.