Auto manufacturing · Michigan

Flat Rock Assembly

Flat Rock, MI · ~2,326 workers · 8 years of OSHA Injury Tracking Application data.

F
Failing Safety Record
7.0
Avg TCR
3.3
Industry avg
0
Fatalities
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The verdict

Flat Rock Assembly runs at 212% of its industry's injury rate - far more dangerous than the typical Auto manufacturing workplace, earning a grade F.

Flat Rock Assembly: 7.0 TCR = 212% of Auto manufacturing BLS 3.3 · 8y Form 300A (see methodology below)

Flat Rock Assembly safety composite

Flat Rock Assembly scores strongest on fatalities (safer than 52% of same-industry peers) and weakest on dart rate (safer than 3%), blended into one 0-100 breakdown against same-industry peers. A missing measure drops out and redistributes its weight rather than deflating the score. This is a per-dimension breakdown, distinct from the single letter grade above it (which weights TCR alone against the BLS industry benchmark).

F

23/100

Percentile-weighted across 3 of 3 measures

Total Case Rate (TCR)
F 7.01 per 100 workers

Safer than 22% of industry peers

DART rate
F 9.81 per 100 workers

Safer than 3% of industry peers

Fatalities
D 0

Safer than 52% of industry peers

Benchmarked live against every credibly-rated employer in the same NAICS industry code in the current OSHA extract (a segment must have at least 8 rated peers to benchmark). Not a legal or compliance determination; PlainSafetyScore's own weighting (TCR 40%, DART 35%, fatalities 25%).

Rising injury rate

Flat Rock Assembly: 6.4 → 10.5 TCR

Peak year 2024 @ 10.5 TCR · DART/TCR 1.4× in 2024

Flat Rock Assembly's TCR rose 4.1 from 6.4 in 2016 to 10.5 in 2024. In 2024, DART was 1.4× this establishment's average TCR (severity share of cases).

OSHA ITA Form 300A scorecard

Establishment book 336111 · Flat Rock, MI ABOVE-IND · LARGE

Grade F · TCR 7.0 · 212% of ind

  • DART 9.8 DART
  • RANK #21/26
  • PHOTO VWGoA Wisconsin PDC
  • BOOK 8y book
  • INJ 755 inj
  • SIZE ~2,326 FTE

Nearest TCR peer: VWGoA Wisconsin PDC (0.0 TCR gap)

Read with this employer → · Industry book → · Michigan employers → · Look up another →

Flat Rock Assembly in the TCR neighbourhood

Average Total Case Rate among this establishment and nearest same-industry peers

TCR

What this shows Flat Rock Assembly averages 7.0 TCR (212% of the Auto manufacturing BLS benchmark).

Source U.S. Department of Labor, OSHA Injury Tracking Application (Form 300A) As of 2026-08-25

Flat Rock Assembly TCR series: 2016=6.4 · 2018=8.8 · 2019=6.1 · 2020=5.5 · 2021=5.2 · 2022=5.5 · 2023=8.1 · 2024=10.5 · BLS 3.3

Where Flat Rock Assembly falls in its industry

158 Auto manufacturing establishments

Safer than 22% of graded establishments in this industry, whose median TCR is 4.4.

More dangerous than peersSafer than peers

Narrower to Michigan alone (the establishments it most directly competes with for workers and contracts): ranked #21 safest of 26 Auto manufacturing employers in Michigan.

Flat Rock Assembly (2,326 employees, TCR 7.0) among 29 same-industry peers, split at the industry median of 366 employees and a TCR of 4.4 2×2 strategic matrix plotting 30 entities by Average employees (X) and Total Case Rate (Y), with a crosshair dividing the plot into four quadrants. Larger & higher-riskSmaller & higher-riskLarger & saferSmaller & safer than peers 05,00010,00015,000 0102030 Average employees Total Case Rate Flat Rock Assembly
Flat Rock Assembly (2,326 employees, TCR 7.0) among 29 same-industry peers, split at the industry median of 366 employees and a TCR of 4.4

Flat Rock Assembly has more employees than the Auto manufacturing median and a higher injury rate than the industry's median TCR of 4.4. Workforce size and injury rate do not always move together within the same industry -- some of its smaller peers run higher rates than its larger ones, and vice versa.

Year-by-Year Safety Data

Year TCR DART Injuries Illnesses Fatalities
2024 10.5 9.8 81 54 0
2023 8.1 6.8 84 49 0
2022 5.5 4.4 61 29 0
2021 5.2 3.7 54 21 0
2020 5.5 3.5 58 27 0
2019 6.1 3.7 121 42 0
2018 8.8 6.0 148 82 0
2016 6.4 2.5 148 68 0

OSHA ITA peer cross-reference

Establishment peer ledger

336111 · MI · Flat Rock

158 Auto manufacturing employers nationwide with a credible TCR · 16,393 rated employers in Michigan with headcount on file · 17 employers in Flat Rock, MI · 4 cross-state NAT-TCR peers · 4 cross-state NAT-SIZE peers. Closest matches by relationship code are listed below.

Rel Establishment Metric
NAICS-TCR VWGoA Wisconsin PDC 7.0 TCR
NAICS-TCR Canton Vehicle Assembly 7.1 TCR
NAICS-TCR Grand Ledge Plant 10 7.0 TCR
NAICS-TCR ResourceMFG/Toyota Motor Manufacturing Kentucky 7.1 TCR
STATE-SIZE STERLING PLNT 2,319 FTE
STATE-SIZE MidMichigan Medical Center - Midland 2,348 FTE
STATE-SIZE West Bloomfield Hosp & Med Ctr 2,356 FTE
STATE-SIZE MGM Grand Detroit 2,277 FTE
CITY-NEAR Flat Rock Metal,Inc. 274 FTE
CITY-NEAR Meijer #278 244 FTE
CITY-NEAR 278 - Flat Rock MI 237 FTE
CITY-NEAR 018-00458 150 FTE
NAT-TCR The Bellevue Hospital 7.0 TCR
NAT-TCR Plainville Store 7.0 TCR
NAT-TCR Winchester Medical Center 7.0 TCR
NAT-TCR Ocean Harvesters, Moss Point, MS Facility 7.0 TCR
NAT-SIZE NXP USA Inc. - Oak Hill 2,326 FTE
NAT-SIZE TXC101551 2,325 FTE
NAT-SIZE Covenant Transport 2,327 FTE
NAT-SIZE Flextronics America LLC - Research Campus 2,327 FTE

Rel codes: NAICS-TCR · STATE-SIZE · CITY-NEAR · NAT-TCR/NAT-SIZE cross-state. Read with this employer →

Data Source: OSHA Injury Tracking Application (ITA), mandatory establishment-level injury/illness reports. Grades compare employer Total Case Rate (TCR) to BLS IIF industry benchmarks. Data covers years reported by this establishment: 2024, 2023, 2022, 2021, 2020, 2019, 2018, 2016. This is publicly available government data - not a legal determination of workplace conditions.

Read our methodology - how this data is sourced, computed, and verified.

Data sourced from official public datasets. See our methodology for details.