Evaluation of the adequacy of maintenance tasks using the failure consequences of railroad vehicles

The purpose of this study is to improve the efficiency, reliability and safety related to railroad maintenance tasks through an evaluation of the consequences of failures. The brake system was selected based on the failure data obtained from railroad vehicles in operation as one of the safety systems in railroad vehicles. The failure causes, failure effects, and the criticality of the failure mode were drawn for 62 failure modes of the braking system through the use of an FMECA for the 30 sub-devices having primary functions. The various maintenance tasks for the braking system were categorized into the 62 failure modes and failure consequences using the FMECA and the logic of maintenance decisions. Braking systems manufactured by the same manufacturer and operated by two different operators were studied in an effort to analyze preventive maintenance and to evaluate the adequacy of preventive maintenance tasks for the 62 failure modes. Based on results of the evaluation of these preventive maintenance tasks, new maintenance tasks were proposed, and concrete cost-cutting effects were determined from the calculation of the maintenance time and expected costs, using a preventive maintenance template developed specifically for railroad vehicles.