Purpose - The purpose of this paper is to provide a new approach involving guidelines and supporting techniques that guarantees all needed space for appropriate product maintenance. Design/methodology/approach - The approach is based on two major areas: field survey to understand how maintainability parameter is applied and converge theory and practice into a systematic space claim method using computer-aided design (CAD) systems to assure proper maintenance procedures at design stages. Findings - Case studies from a truck industry conducted following the proposed approach contrast the savings that can be achieved by using a proper space claim for aftermarket needs against an unsuitable level of participation by maintenance personnel during the design development. Research limitations/implications - This approach is highly dependent on maintenance experts with suitable skills on CAD systems. Practical implications - Products developed according to the approach envisaged can result in following aspects: lower repair time, better maintenance procedures on key components, easier preventive maintenance, less need for special tools, more ergonomic design, better communication between design and service engineers, simplicity and less complex training. Social implications - Further research on maintainability will provide new information on how to apply this parameter on product development process (PDP), so design teams can better understand and address this relevant issue. The proposed method has been introduced in the PDP of a major multinational automotive company. Originality/value - A new process is presented, considering the protection of needed spaces for maintenance procedures throughout the PDP, diverging to other studies that only propose analysis addressing maintainability at singular point in time during the product development. In just one case study presented, savings of US$1.3m were achieved by applying this space claim approach.