Risk and Reliability Evaluation of Future Industrial Automation Systems: A Systematic Literature Review and Research Agenda

Morozov, Andrey; FABARISOV, Tagir; Vock, Silvia; Siedel, Georg; Bolbot, Victor; Voß, Stefan

doi:10.1115/1.4070764

Article (Scientific journals)

Risk and Reliability Evaluation of Future Industrial Automation Systems: A Systematic Literature Review and Research Agenda

Morozov, Andrey; FABARISOV, Tagir; Vock, Silvia et al.

2026 • In ASCE-ASME Journal of Risk and Uncertainty in Engineering Systems, Part B: Mechanical Engineering, p. 1-44

Peer reviewed

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https://hdl.handle.net/10993/67405

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10.1115/1.4070764

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Abstract :

[en] Today, terms such as Sustainable Production, Industrial Cyber-Physical Systems, Cyber-Physical Production Systems (CPPS), Software-Defined Manufacturing, Smart Manufacturing, Industry 4.0, Industry 5.0, System of Systems, Internet of Things, Human-in-the-Loop, and Digital Twins are widely used. These concepts emphasize key characteristics of modern and future production systems, including heterogeneity, structural and behavioral complexity, intelligence, autonomy, reconfigurability, and human centrism. They also highlight the growing importance of reliable and up-to-date risk assessment, safety, and reliability measures, given the significant environmental, economic, and social demands. However, current industrial risk analysis methods lag behind the rising technical sophistication of such systems. It remains unclear whether existing methods can capture complex failure scenarios of dynamic, AI-driven systems with advanced software architectures.This paper discusses the main challenges facing safety engineers in industrial automation. We provide a classification and overview of available risk and reliability analysis methods and metrics, supported by a systematic review of 95 papers up to October 2025. The review addresses questions such as: which CPPS aspects must be considered, which methods are applicable, what are their advantages and limitations, and how can methods be combined? The findings reveal the need to extend classical approaches toward dynamic risk assessment, probabilistic model checking, AI-based techniques, digital twins, and intelligent fault injection. The study provides both a comprehensive overview of current risk and reliability assessment methods for CPPS and a roadmap for advancing their future development.

Precision for document type :

Review article

Disciplines :

Electrical & electronics engineering

Author, co-author :

Morozov, Andrey; University of Stuttgart, Stuttgart, Germany

FABARISOV, Tagir ; University of Luxembourg > Interdisciplinary Centre for Security, Reliability and Trust (SNT) > SerVal

Vock, Silvia; Bundesanstalt für Arbeitsschutz und Arbeitsmedizin, Dresden, Germany

Siedel, Georg; Bundesanstalt für Arbeitsschutz und Arbeitsmedizin, Dresden, Germany

Bolbot, Victor; Aalto University, Helsinki, Finland

Voß, Stefan; Bundesanstalt für Arbeitsschutz und Arbeitsmedizin, Dresden, Germany

External co-authors :

yes

Language :

English

Title :

Risk and Reliability Evaluation of Future Industrial Automation Systems: A Systematic Literature Review and Research Agenda

Publication date :

06 January 2026

Journal title :

ASCE-ASME Journal of Risk and Uncertainty in Engineering Systems, Part B: Mechanical Engineering

ISSN :

2332-9017

eISSN :

2332-9025

Publisher :

ASME International

Pages :

1-44

Peer reviewed :

Peer reviewed

Additional URL :

https://asmedigitalcollection.asme.org/risk/article-pdf/doi/10.1115/1.4070764/7582785/risk-25-1078.pdf

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since 22 January 2026

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