In this paper, the structural analysis and optimization of the door supporting rail structure in the header box located at the top of the aluminum passenger safety door(PSD) at the subway station, which opens and closes regularly, is performed. In case the simple fixed boundary condition is used for the bolt fixture on the supporting rail where the glass door is moving, excessive stresses are obtained. Therefore, more realistic finite element modeling of the bolts is used at the bolt fixture in the whole structure in order to obtain the more physically acceptable FEM results. As a result, fatigue life of twenty years of the structure is obtained to satisfy the design object. Also the optimal design of cross section of the rail part is performed using the response surface method and 15% of weight of the supporting rail part on the door is reduced.