In order to maintain and improve company profitability especially during financial crises and lower profit-margin, it is necessary to reduce economic losses. This can be achieved through maintaining and improving the quality of the elements involved in the production process. Therefore, the maintenance strategy applied should be dynamic to suit the changes occur in a production process cost-effectively. Therefore, it is essential for maintenance and production managers to have a system providing the data required to achieve dynamic and cost-effective maintenance decisions. In this paper, a new Maintenance Decision Support System (eMDSS) for achieving dynamic and cost-effective maintenance decisions is introduced, tested and discussed. It consists of three toolsets and five software modules for performing six services to; enhance accuracy of maintenance decisions, select the most cost-effective maintenance solutions, identify and prioritise problem areas, and assess losses in production time, and map, follow up and assess maintenance cost-effectiveness (maintenance savings and profit) to achieve continuous & cost effective improvement. The major result of this tsudy is verfication of a new innovative Mainteance Decision Support System (eMDSS). The system has been tested at Fiat (car manufacturer)/CRF in Italy and GORATU (CNC-machine manufacturer).  The main conclusion is; applying eMDSS it is possible to map production and maintenance processes, identify and prioritise problems, select the most cost-effective maintenance investment and follow up and control investments results.