In general, all the elements involved in a production process, such as tools, machinery, methods, competence and working environment are exposed to dynamic changes. Thus, in order to maintain and improve company profitability and competitiveness especially during financial crises and lower profit-margin, it is necessary to reduce losses through maintaining and improving the quality of the elements involved in the production process. Therefore, the maintenance strategy applied should be dynamic to follow all these changes cost-effectively. The accuracy of maintenance decisions is essential for reducing economic losses generated due to unnecessary stoppages especially when stoppage time is very expensive. Therefore, it is necessary for maintenance and production managers to have a system providing the data required to achieve dynamic and cost-effective maintenance decisions. In this paper, the role of & importance of dynamic and cost effective maintenance in company business is discussed. Also, a scenario for applying a new eMaintenance Decision Support System (eMDSS) for achieving dynamic and cost-effective maintenance decisions is introduced, tested and discussed. eMDSS introduces four different strategies for continuously improving the cost-effectiveness of maintenance and production processes. It consists of three toolsets and five software modules for performing six services to;

1. enhance accuracy of maintenance decisions

2. select the most cost-effective maintenance solutions

3. identify and prioritise problem areas, and assess losses in production time

4. map, follow up and assess maintenance cost-effectiveness (maintenance savings and profit) for achieving continuous & cost effective improvement.

The major result of this tsudy is a new innovative eMDSS. The system has been tested at Fiat (car manufacturer)/CRF inItalyand GORATU (CNC-machine manufacturer).  The main conclusion is; applying eMDSS it is possible to map production an maintenance processes, identify and prioritise investments results.