A worker builds cars on the assembly line at Ford's Chicago Assembly plant, which has adopted the "three crew" work schedule. The new third shift can increase efficiency in factories, but it can also wreak havoc on sleep needs and home lives.
As car companies struggle to meet growing demand, the third shift is making a comeback. But many factories running on three shifts are doing it differently from in the past. And that new "three crew" shift pattern could make what's normally a hard job even harder.
At Ford's Michigan Assembly Plant in Wayne, employees work 10-hour shifts four days a week. The so-called A crew gets days, while the B crew gets afternoons. But the C crew shift rotates its start time every week. On Fridays and Saturdays, workers start at 6:00 a.m. On Mondays and Tuesdays, they start at 4:30 p.m.
Paul Schubert and his wife decided to buy a new car last summer — a really fuel-efficient one. After a lot of research, they settled on a Toyota Prius. But there was a problem: They couldn't find one.
The tsunami that devastated Japan in March had dried up supplies of the Prius, which is made in Japan, and a dealer told them they would have to wait — "about four months," Schubert says. "And we thought, well, it'd be, probably, end of November, early December before we were going to have a car."