A Defense product can be subjected to a broader and deeper maintenance process, which aims to extend its service life. Analyzing data from 48 overhauled armored fighting vehicles (AFV), almost 65% of components designated to maintenance have low replacement rates (less than 30%), requiring a probabilistic approach for management of replacement rate due to a possibility of reuse. This implies in some uncertainty during overhaul planning, which could be extended to production phase. A five-step approach centered in risk management is proposed to overhaul projects. In this approach, a risk-based decision model intends to deal with elements designated to maintenance, by defining what to do and how many spare parts are necessary during overhaul. A case is proposed to illustrate the model in a major overhaul program of an AFV performed in a Brazilian Army depot. The model contributes to a better decision making to support engineering role in a major -overhaul design.
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