I'm trying to be ready for scenarios at paragon tier where the PCs have a ship with 20 or 30 crew on board, and they go up against similar ships of bad guys.
If I put a normal encounter worth of bad guys as the officers of the enemy ship, I'm still rolling dice for an extra 40 people. While I fondly recall spending days running 40-mech slogs in Battletech back when I was in high school, that much dice rolling is untenable for me nowadays.
So it looks like the options are either 'hand wave it,' or 'have simple rules.' I personally would go for hand wave, but since I'm working on this for a published product, I want to have rules available for folks who like rules.
Really Rules Light - Crew
Crew are a new variety of minion, specially designed for use on cramped ships, where a scene might call for dozens of foes, but you don't want to slow the game down by running them with normal minion rules. 'Crew' can easily represent soldiers in a huge battle, or members of a mob during a riot.
Do not use miniatures for crew. Instead, mark each crew member with a flat counter (such as a coin) that won't get in the way of other miniatures. If two ships' crews are involved in the same encounter, use different types of counters.
Crew never act on their own, and do not even move unless commanded or subjected to forced movement.
Non-crew creatures can enter and share spaces with crew, even hostile crew. The space a crew member occupies counts as difficult terrain. Creatures that enter the space of a hostile crew member take 5 points of damage (10 points at paragon tier, 15 at epic).
Attacks can target and affect crew just like normal minions, but only damage and forced movement matters. If an attack inflicts a condition such as blinded, dazed, deafened, immobilized, prone, restrained, slowed, stunned, or weakened, it does 1 damage to the crew member. The exception is that a missed attack still does never damages a crew member. Crew cannot gain temporary hit points.
Crew who are allied with the PCs are not killed when reduced to 0 hit points. Instead they are knocked unconscious. If tended to within an hour, they regain consciousness after a short rest and return to 1 hit point. If left untended for an hour, they die. Likewise they die if someone goes to the effort of delivering a coup de grace.
As a standard action, a character or creature can command allied crew. That character chooses four allied crew members it can see within 10 squares, and moves them with a speed of 6. Crew can move through allies' spaces (including allied crew), and can end their movements in the spaces of allied non-crew creatures. They cannot end their movement in a space occupied by allied crew.
If a crew member enters the space of a hostile crew member, both are reduced to 0 hit points. If a crew member enters the space of a hostile non-crew creature, its movement stops, and that creature takes 5 damage (10 at paragon, 15 at epic).
Crew Template - Military
When a character commands military crew, instead of moving them he can have each crew member deal 5 damage (10 at paragon, 15 at epic) to one creature adjacent to it.
Crew Template - Sorcerous
When a character commands sorcerous crew, instead of moving them he can have each crew member push a creature within 5 squares 1 square.
Crew Template - Supernatural
This represents undead or other magically resilient creatures. When a crew member enters the space of a hostile crew member, if one is supernatural, only the non-supernatural crew member is destroyed. If both are supernatural, both are destroyed.
There. That should be stupidly fast to run.