1. A method for identifying a hidden process near-miss in a plant/facility operation, the method comprising: collecting measured data associated with at least one process variable, although without related adverse incident; collecting long-term process data; determining normal values or value ranges, or combinations thereof, based on long-term process data, and comparing the measured data associated with the at least one process variable with the collected long-term process data to determine deviation there between measured data relative to determined normal value(s), wherein a measure or extent, or both, of the deviation identifies at least one hidden process near-miss.