>> How can you do a fault tree analysis before things go wrong?
Formal fault tree analysis has been used byt the nuclear power industry for decades. You may consult the "Fault Tree Handbook" also known as NUREG-0492 which can be found here:
http://www.nrc.gov/reading-rm/doc-collections/nuregs/staff/s...
It has been adopted in parts of the auto industry for at least a decade (I was directly exposed to this).
You start with a preliminary hazard analysis based on what could go wrong and work backward through the system to identify things connected to the component in question that would lead to the undesired outcome. You'll build a large binary circuit where the inputs are events or problems and the output is a failure. The tools can do an analysis to determine what combinations can lead to that failure. If the simplified boolean expression contains any single terms, you have a single point of failure that will lead to the undesired outcome. You then redesign the system so that no single point failures lead to disaster.
THIS ANALYSIS HAS TO BE DONE BEFORE YOU BUILD IT TO BE ANY GOOD.
I always liked this way better than the more common "faulure modes and effects analysis" or FMEA, which makes you try to determine system-wide consequences of component failures - often down to individual resistors. These do find problems at design time, but IMHO it's too much work. With a fault tree you get to treat larger assemblies as a component.