An intelligent computer integrated maintenance system and method includes an electronically stored parts manual which contains a hierarchical listing of all parts in production machines, and a maintenance operations computer controller which includes a maintenance schedule management subsystem, an engineering change control subsystem, a parts manual management subsystem and a spares inventory management subsystem. The maintenance schedule management subsystem obtains a schedule of actual and planned production, and groups maintenance activities in order to minimize lost production time. The engineering change control subsystem integrates engineering change activities with maintenance activities to maximize production time. The automated parts manual is also updated to account for engineering changes. The spare parts inventory management subsystem orders spare parts based on predicted maintenance rather than on prescribed inventory levels. Production efficiency is thereby maximized, as is the use of available maintenance manpower. Engineering changes are easily accommodated and spare parts inventory is kept to a minimum.