Weary
I also work for a company operating a 30 tonne mach .6 a/c where the discussion of TOLD cards has come up.
Possibly even the same company, as it would be typical to task one guy with the design rather than use resource management and put the shout round within the company that change was in the offing and has anyone got any ideas based on past experience.
The problem with having pre-printed cards which cover all the variations you list is that you almost find yourself recreating the runway analysis tables and end up with an enormously thick pad of cards. For example if you have weight steps from 20 to 30 tonnes in half tonne steps then allow two flap settings for each weight you have 40 pages, before you get into wet/contaminated runways etc.
Probably the best thing is a blank laminated card with boxes for
TOW
Flap setting
V1
Vr
V2
Vfri
Vclimb
Acceleration height/altitude
Immediate return flap setting
Vapp
Vref
And for each sector spend a couple of minutes extracting the required information from the runway analysis table and then write it on the card with a chinagraph.