The increasing complexity of operational maintenance on naval platforms and the need to sustain this also in battle conditions are in conflict with the requirement for crew reduction. This asks for a new approach. The Netherlands MoD knows how to develop technical solutions for operational maintenance support, but it lacks knowledge on human factors, cognitive engineering and design methods as part of an integrated design philosophy towards the optimal balance between man, technology and organisation. This knowledge needs to be applied to the design of future platforms. In a two-year programme, TNO developed this knowledge, with the specific aim to demonstrate a suite of methods for analysis, design, simulation and evaluation of future operational maintenance concepts (including support and education & training), and to test this suite in a realistic and concrete operational maintenance scenario with reduced technical manning and expertise. A selected set of analysis methods were applied to the current operational maintenance on-board the RNLN OPV. This included extensive observations on board, descriptive work modelling and workload assessment, which enabled us to identify which parts of the work are more and less knowledge-intensive, and eligible earlier or later for automation, mechanization or support. By practicing selected methods for design, simulation and evaluation, we achieved an innovative operational maintenance concept, in terms of a new way of working, crew composition and support tools for future operational maintenance. At the same time, we reviewed the individual and combined usefulness of the methods.