returns are pretty low for me atm as I'm running 3-4 yo hardware (GPUs and FPGA). So maybe 5/day/rig. Top of the line ASICs are doing 30/day or so atm. This after subtracting pwr. I'm planning to move across the country so haven't bothered upsizing.
Time was substantial when I started as the amount of dedicated hardware and software was lower than it is now so there were uptime issues all the time. Now that there's dedicated hardware and software out, maybe an hr a day at most. Keep in mind this is as much a hobby as it is a passive income stream, so I don't stress too much if I have a rig go down. Now a days you have email notifications, remote monitoring and rebooting thru your phone, and hardware watchdogs so it's easier to keep rigs online. ASICs are pretty fool proof so manpower's negligible unless you get a lemon.
It's definitely scalable for a one man team, it's what's so great about it. The limiting factor is space, money, infrastructure (power), and know-how. From what I've learned, it takes me less than an hr to build a rig and have it up and running. ASICS, maybe 10-15 mins.
The last question's the wild card honestly and difficult to answer. It depends on how much you went in at, if you overpaid for hw, if you didn't fuck up buying the wrong hw, and obviously the price volatility.
One thing that was a common fuck up for instance was buying an ASIC and then a competitor releasing theirs w/double the hashrate making your machine a brick. It used to be also that manufacturers would have pre-sales and then not deliver on time or another comp. would release before they did making your purchase a bad one. To avoid that, you have to buy from the top dogs and reputable vendors w/a history of delivering at the promised day/week
Everything that's decent's coming out of China so there's speculation that they're always building and running something better and maybe even selling you rigs they've been running for months and giving them a shine before boxing them up. The likelier scenario is they're running upscale custom machines themselves for private farms. What I've noticed is they're building them w/razor thin specs, in essence guaranteeing you'll be back in 6 months for their shinier model. It's incredibly wasteful tbh.