Weight & Balance Management
Flight Operations › Flight Dispatch & Control · 17 L4 steps · 5 phases · 7 decision gates · Updated 2026-03-18 22:42
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Process Flow Diagram (BPMN)
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L4 Process Steps
| Step | Step Name | Role / Swim Lane | System | Input | Output | KPI | Dec? | Exc? |
|---|---|---|---|---|---|---|---|---|
Phase 1 1.1 |
Pull aircraft DOW/DOI from maintenance system | Load Controller | AMOS by Swiss AviationSoftware | Tail number assignment from OCC | Dry Operating Weight, Dry Operating Index, seating config, hold bay limits | Configuration accuracy 100%; zero dispatches with incorrect DOW | N | Y |
| 1.2 | Retrieve fuel uplift from flight planning system | Load Controller | Lido/Flight by Lufthansa Systems | Signed flight plan released by dispatcher | Fuel figure (trip, contingency, alternate, final reserve) in kg for load calculation | Fuel data transfer latency < 5 min from dispatch plan release | N | N |
| 1.3 | Calculate structural limits and underload allowance | Load Controller | SITA LoadManager | DOW, fuel load, aircraft type structural limits (MTOW, MZFW, MLW, MAC envelope) | Maximum payload, underload figure, allowed traffic load by cabin and hold | Underload figure accuracy ±50 kg versus final actuals | Y | N |
Phase 2 2.1 |
Extract PAX counts from check-in at cutoff | Load Controller | Amadeus Altéa PSS | Departure control check-in data at standard cutoff (T-35 min) | Final passenger counts by cabin class; PAX weight totals using standard weights | Cutoff-to-load-sheet cycle time < 15 min | N | Y |
| 2.2 | Apply IATA standard or actual PAX weights | Load Controller | SITA LoadManager | PAX count, season flag, route type (domestic/international), cabin class mix | Total PAX weight per IATA Resolution 788 (84 kg male / 76 kg female with carry-on) | Weight deviation vs actuals < 2% for domestic routes | Y | N |
| 2.3 | Capture checked baggage weights at bag room | Baggage Handler / Load Controller | SITA BagManager | Baggage tag scans at make-up area belt | Per-flight total hold baggage weight by zone and ULD | Baggage weight reconciliation ≥ 99% of tagged bags per flight | N | Y |
| 2.4 | Process special PAX categories from SSR codes | Load Controller / Ground Service Agent | Amadeus Altéa PSS | SSR codes (UMNR, WCHC, EXST, BSCT, MEDA) from reservation record | Special category weights and seating constraints applied to load plan | SSR compliance rate 100%; zero unmanaged special PAX categories at load sheet issue | N | Y |
Phase 3 3.1 |
Receive cargo manifest and ULD build data | Load Controller | CargoWise / SITA AMS | Air waybill manifest, ULD build sheets from cargo acceptance | Cargo weight, volume, and loading sequence by hold bay | Cargo manifest received ≥ T-60 min before departure; late manifest rate < 5% | Y | Y |
| 3.2 | Validate and approve DG load — issue NOTOC | Load Controller / DG Acceptance Agent | Cargospot by SITA | DG declaration, ICAO packing group, quantity and UN number | Approved DG stowage position; NOTOC transmitted to captain via ACARS | DG NOTOC issued to captain ≥ T-30 min before departure; 100% ICAO Annex 18 compliance | Y | Y |
| 3.3 | Allocate hold bay loading positions for CG target | Load Controller | SITA LoadManager | Cargo weight and volume by ULD, DG stowage rules, ZFW CG target | Bay loading plan (fwd/aft hold, bulk), tie-down instructions for ramp crew | CG within ±1% MAC of target after initial bay allocation | N | N |
Phase 4 4.1 |
Generate preliminary e-LoadSheet with ZFW/TOW/LDW | Load Controller | SITA LoadManager | PAX weights, baggage weights, cargo bay plan, fuel load, DOW | Preliminary ZFW, TOW, LDW, CG %MAC on electronic Load Sheet | Preliminary load sheet ready ≥ T-30 min before scheduled departure | N | Y |
| 4.2 | Validate CG within certified flight envelope | Load Controller | SITA LoadManager | TOW and CG %MAC from preliminary load sheet | CG validation result — pass or fail against fwd and aft certified limits | CG out-of-envelope rate < 0.01% of departures (IATA industry benchmark) | Y | Y |
| 4.3 | Calculate stabiliser trim setting and confirm CG index | Load Controller / Captain | SITA LoadManager / Jeppesen FliteDeck (EFB) | Final TOW, CG %MAC, selected flap setting | Stab trim setting transmitted to captain; load sheet CG index confirmed | Stab trim setting issued to flight deck ≥ T-20 min before departure | N | Y |
| 4.4 | Transmit final load sheet to flight deck via ACARS | Load Controller | SITA ACARS / Jeppesen FliteDeck (EFB) | Finalised and signed e-LoadSheet | Load sheet delivered to flight deck; ACARS receipt confirmation captured | Load sheet delivery ≥ T-20 min before departure; ACARS receipt confirmation within 2 min | N | Y |
Phase 5 5.1 |
Captain reviews and signs load sheet on EFB | Captain / First Officer | Jeppesen FliteDeck (EFB) | e-LoadSheet, stab trim, NOTOC, and fuel plan | Captain's electronic signature on load sheet; acceptance transmitted to load control | Captain acceptance cycle time < 5 min; load sheet rejection rate < 0.5% | Y | Y |
| 5.2 | Issue final loading instruction and close holds | Load Controller / Ramp Supervisor | SITA AMS (Airport Management System) | Accepted load sheet, finalised bay loading plan | Final loading instruction transmitted to ramp; hold door closure authorised | Hold closure notification ≥ T-10 min before departure; D0 on-time departure impact attributable to W&B < 0.3% | Y | Y |
| 5.3 | Archive load sheet and transmit LDM to destination | Load Controller | SITA LoadManager / Telex ACARS | Signed load sheet; final PAX, cargo, and fuel actuals | Load Distribution Message (LDM) transmitted to destination station and OCC; load sheet archived per ICAO Annex 6 (24-month retention) | LDM transmitted within 5 min of actual departure; 100% archival compliance rate | N | Y |
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