How FAST Global Solutions partnered with Envoy Airlines to address a stair positioning safety risk on the ramp.
Customer Challenge
Envoy identified a recurring operational risk on the ramp: boarding stairs must be positioned at the correct height beside the aircraft to avoid contact as the aircraft settles during loading and servicing. When stairs are set too high or too low, the result can be more than a minor adjustment. It can lead to aircraft damage, added inspections, service delays, and preventable safety exposure for ramp personnel.
The challenge exists within a broader industry context. The Flight Safety Foundation estimates that roughly 27,000 ramp accidents and incidents occur worldwide each year, while IATA has reported that belt loaders, cargo loaders, passenger stairs, and boarding bridges account for about 40% of total ground-damage incidents. These findings reinforce a simple reality: small improvements in ramp equipment design can have an outsized impact on safety and reliability.
IATA estimates the annual cost of aircraft ground damage is about $5 billion today and could approach $10 billion by 2035 without broader preventive action, making ramp safety improvements both a safety priority and a strong business case.
FAST Solution
FAST Global Solutions partnered with Envoy to develop a more durable and repeatable way to help operators position boarding stairs correctly at the aircraft. Rather than relying on a basic decal or temporary visual indicator, FAST engineered a stair-height indicator with clear positioning references designed for frequent use in real ramp conditions.
This solution reflects FAST’s broader approach to equipment design: build practical safeguards that support frontline teams, reduce the opportunity for human error, and improve operational consistency. As the aviation industry continues to emphasize enhanced ground support equipment and better proximity control, FAST’s design philosophy aligns with the direction safety leaders are already advocating.
Implementation
Envoy involved stakeholders from ramp operations, safety, and frontline teams to review and validate the feature before rollout. That cross-functional engagement helped ensure the solution was technically sound and practical for the people using it every day. By designing around real operating conditions, FAST delivered a solution that fit the workflow rather than adding complexity to it.
Business Impact
The result is a stronger, more intentional approach to ramp safety. The stair-height indicator helps reduce the likelihood of avoidable aircraft contact while supporting smoother turn processes and better equipment use. For Envoy, the value is practical: less reliance on visual judgment, more consistency in day-to-day operations, and a solution shaped around the realities of the ramp.
For FAST, this project demonstrates the company’s role as more than an equipment manufacturer. It shows FAST as a partner and solution provider that understands how safety, uptime, and operational performance intersect, and how thoughtfully engineered improvements can help airlines protect people, equipment, and schedule integrity.