Benefits and Drawbacks of 12-hour Shifts in Steel Manufacturing: a Comprehensive Qualitative Investigation of Workers, Managers, and Family Perspectives

Abstract

This study examined the implications of 12-hour shifts in steel manufacturing through a qualitative analysis of workers, managers, and family perspectives. Using grounded theory methodology at Mobarakeh Steel Company, researchers conducted semi-structured interviews with 150 operators, 32 managers/supervisors, and 50 family members, revealing complex trade-offs across stakeholder groups. While operators appreciated increased family time and reduced commuting, they reported significant fatigue and health concerns. Management acknowledged operational benefits like fewer shift handovers and improved task completion, but expressed serious concerns about safety risks and productivity decline during extended hours. Family members valued longer rest periods and economic advantages but noted disrupted domestic routines and concerning health patterns in their working spouses. All groups consistently identified substantial fatigue-related challenges during the final hours of 12-hour shifts. Though the extended shift system offered certain advantages such as increased consecutive days off and reduced commuting frequency, these benefits were outweighed by significant concerns regarding worker health, safety, and family dynamics. The study concluded that successful implementation of extended shifts in steel manufacturing necessitates careful consideration of diverse stakeholder needs and development of targeted risk mitigation strategies.