If you’ve ever been on an airport ramp during a turnaround, you know time isn’t on your side. From touchdown to takeoff, crews get about thirty minutes to unload, service, reload, and push back the aircraft. That’s not a lot of time. Every second counts and every delay carries a hefty price.
In 2023, U.S. airlines spent an average of $100.80 per block minute according to Airlines for America. Multiply that across thousands of flights each day, and it’s no surprise the FAA estimates delays cost U.S. carriers $32.9 billion annually. The data from Europe helps explain where these delays are coming from. In 2023, Eurocontrol reported that airline-controlled issues, like ramp handling and boarding, were the second leading cause of delays.
The turnaround window is already razor thin. When communication breaks down, the entire schedule starts to slip.
The cost of poor communication becomes most obvious when we look at baggage errors. SITA’s 2024 Baggage IT report found airlines mishandled 33.4 million bags worldwide, or about 6.3 mishandled bags for every 1,000 passengers. This resulted in more than $5 billion in losses for airlines. A large number of these errors happen during transfers, when crews are under pressure and dealing with last-minute changes. Maybe a late check-in bag shows up just as the gate is shifting, or an oversized item needs special handling. Without clear, timely instructions, those everyday situations can quickly turn into expensive mistakes.
Technology is helping, of course. RFID tags can now track bags through airports, and the International Air Transport Association (IATA) expects most airlines to adopt these tags in the next few years. But even RFID has limits. A tag only shows where a bag is, not what needs to be done with that bag. That decision still depends on someone receiving and acting on the right message at the right time. Clear communication remains essential for quick turnarounds.
Communication breakdowns also show up in safety data. Ramp work is loud, fast, and full of moving equipment. It’s no surprise the Flight Safety Foundation estimates ground damage costs airlines at least $10 billion a year, and warns the number could rise if nothing changes. They also report that about 243,000 people are injured annually in ramp incidents.
Human factors account for the vast majority of these ramp accidents, with poor communication consistently serving as one of the leading causes. Coordinating teams under tight time pressure is tough. Try doing it beside a roaring jet with a crackly walkie talkie and it’s almost impossible. In that chaos, details slip, mistakes pile up, and ramp workers get hurt. Failed communication doesn’t just cost money — it puts workers at risk.
There’s no question about the need for better communication. The numbers speak for themselves. The real question is whether airlines will keep patching old tools or move to something that actually fits the ramp. That’s where Zello comes in. Zello is an app that turns any smartphone or rugged device into a push-to-talk radio. Crews connect instantly, hear clearly even in noisy environments, and replay messages whenever needed. Managers can pin key instructions so they stay visible across shifts. For ground and airline crews handling baggage and equipment under tight deadlines, that means fewer errors, smoother handoffs, and safer operations.
Radios weren’t built for today’s ramp. Zello is.
See how Zello helps ground teams stay connected and keep turnarounds on track. Ready to learn more?