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Opportunistic maintenance gives the maintenance crew an opportunity to replace or repair those items, which are found to be defective or needs replacement in the immediate future, during the maintenance of a sub‐system or a module. This paper tries to address the questions of how to decide whether a particular item needs opportunistic maintenance, and if so how cost effective the opportunistic maintenance is in comparison to a later grounding. These questions play an important role, especially in case of complex systems containing expensive items with hard lives and condition monitoring maintenance strategies. A systematic analysis of selection of components that require opportunistic maintenance is carried out, after which genetic algorithms are used to decide whether opportunistic maintenance is cost effective or not. A hypothetical example is used to describe the methodology for genetic algorithms.

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