Risk priority number (RPN) is a widely used approach, and it is a powerful means to assess the criticality of modes in a failure modes, effects, and criticality analysis (FMECA) worksheet. In the application of the traditional FMECA, the RPN is determined to rank the failure modes; however, the method has been criticized several times for having many drawbacks and weaknesses, such as the presence of gaps in the range of admissible values, the duplicates value provided by different combinations of the base factors, and the high sensitivity to small changes. This paper analyses and compares some alternative RPN formulation proposed in the literature to overcome these limits. This paper takes into account only the alternative RPN, which proposes a powerful solution without increasing the computational complexity and remaining coherent to the classical idea included in the international standard IEC 60812. In order to compare the advantages and disadvantages of these alternative RPNs, an FMECA was developed for a heating, ventilation, and air condition (HVAC) system in railway application. The critical analysis of the comparison can provide recommendations and suggestions regarding the choice of the alternative RPN based on the type of application. Finally, this paper takes into account the scales reduction of possible values related to the parameters (i.e., occurrence, severity, and detection), which influence the assessment of the RPN. This approach allows the designers to mitigate the drawbacks related to the full scale and provide an easier and faster assessment of the scores to evaluate the criticality analysis and prioritization.

Wireless Sensor Networks are subjected to some design constraints (e.g., processing capability, storage memory, energy consumption, fixed deployment, etc.) and to outdoor harsh conditions that deeply affect the network reliability. The aim of this work is to provide a deeper understanding about the way redundancy and node deployment affect the network reliability. In more detail, the paper analyzes the design and implementation of a wireless sensor network for low-power and low-cost applications and calculates its reliability considering the real environmental conditions and the real arrangement of the nodes deployed in the field. The reliability of the system has been evaluated by looking for both hardware failures and communication errors. A reliability prediction based on different handbooks has been carried out to estimate the failure rate of the nodes self-designed and self-developed to be used under harsh environments. Then, using the Fault Tree Analysis the real deployment of the nodes is taken into account considering the Wi-Fi coverage area and the possible communication link between nearby nodes. The findings show how different node arrangements provide significantly different reliability. The positioning is therefore essential in order to obtain maximum performance from a Wireless sensor network.

This paper develops a Failure Mode, Effects and Criticality Analysis (FMECA) for a heating, ventilation and air conditioning (HVAC) system in railway. HVAC is a safety critical system which must ensure emergency ventilation in case of fire and in case of loss of primary ventilation functions. A study of the HVAC’s critical areas is mandatory to optimize its reliability and availability and consequently to guarantee a low operation and maintenance cost. The first part of the paper describes the FMECA which is performed and reported to highlight the main criticalities of the HVAC system under analysis. Secondly, the paper deals with the problem of the evaluation of a threshold risk value, which can distinguish negligible and critical failure modes. Literature barely considers the problem of an objective risk threshold estimation. Therefore, a new analytical method based on finite difference is introduced to find a univocal risk threshold value. The method is then tested on two Risk Priority Number datasets related to the same HVAC. The threshold obtained in both cases is a good tradeoff between the risk mitigation and the cost investment for the corrective actions required to mitigate the risk level. Finally, the threshold obtained with the proposed method is compared with the methods available in literature. The comparison shows that the proposed finite difference method is a well-structured technique, with a low computational cost. Furthermore, the proposed approach provides results in line with the literature, but it completely deletes the problem of subjectivity.

The International Union of Railway provides an annually safety report highlighting that human factor is one of the main causes of railway accidents every year. Consequently, the study of human reliability is fundamental, and it must be included within a complete reliability assessment for every railway-related system. However, currently RARA (Railway Action Reliability Assessment) is the only approach available in literature that considers human task specifically customized for railway applications. The main disadvantages of RARA are the impact of expert’s subjectivity and the difficulty of a numerical assessment for the model parameters in absence of an exhaustive error and accident database. This manuscript introduces an innovative fuzzy method for the assessment of human factor in safety-critical systems for railway applications to address the problems highlighted above. Fuzzy logic allows to simplify the assessment of the model parameters by means of linguistic variables more resemblant to human cognitive process. Moreover, it deals with uncertain and incomplete data much better than classical deterministic approach and it minimizes the subjectivity of the analyst evaluation. The output of the proposed algorithm is the result of a fuzzy interval arithmetic, α-cut theory and centroid defuzzification procedure. The proposed method has been applied to the human operations carried out on a railway signaling system. Four human tasks and two scenarios have been simulated to analyze the performance of the proposed algorithm. Finally, the results of the method are compared with the classical RARA procedure underline compliant results obtain with a simpler, less complex and more intuitive approach.

Reliability-centered maintenance (RCM) is a well-established method for preventive maintenance planning. This paper focuses on the optimization of a maintenance plan for an HVAC (heating, ventilation and air conditioning) system located on high-speed trains. The first steps of the RCM procedure help in identifying the most critical items of the system in terms of safety and availability by means of a failure modes and effects analysis. Then, RMC proposes the optimal maintenance tasks for each item making up the system. However, the decision-making diagram that leads to the maintenance choice is extremely generic, with a consequent high subjectivity in the task selection. This paper proposes a new fuzzy-based decision-making diagram to minimize the subjectivity of the task choice and preserve the cost-efficiency of the procedure. It uses a case from the railway industry to illustrate the suggested approach, but the procedure could be easily applied to different industrial and technological fields. The results of the proposed fuzzy approach highlight the importance of an accurate diagnostics (with an overall 86% of the task as diagnostic-based maintenance) and condition monitoring strategy (covering 54% of the tasks) to optimize the maintenance plan and to minimize the system availability. The findings show that the framework strongly mitigates the issues related to the classical RCM procedure, notably the high subjectivity of experts. It lays the groundwork for a general fuzzy-based reliability-centered maintenance method.