Currently aircraft maintenance cost exactly the same for every part regardless of the state of the part in question. Just make it so the cost takes into account the current state of the part. Just for example. Some part cost 1000 CR to maintain, but current state is 94,5%,then it should cost not whole 1000 CR to maitain, but only 55 CR.
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I think the reason for that is because in real life, when you do maintainance on a part you generally end up replacing it.
For example:
- You replace the oil in the engine, it doesn’t matter whether you last changed it 10 minutes or 10 months ago, you throw the old oil away and have to buy all new.
- The tyres are slightly worn so you replace them, it doesn’t matter how worn they are, the cost to buy new ones is always the same.
- A new battery, you throw the old one away no matter how old it is or what condition it is in, the cost of a new battery from the shop/supplier is always the same.
There are actually very few parts that you can maintain without replacing due to wear.
The way around this is to play somewhat realistically. You wouldn’t replace tyres in real life because they are at 95% state, you’d replace them when they were worn down to 25% or something like that (or in this case, whatever percentage makes sense for the game failure rate mechanics) 