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
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.
- F
- Failing Safety Record
- 7.0
- avg TCR · per 100 workers
- 3.3
- industry benchmark (BLS)
- 755
- recordable injuries tracked
Grade compares Flat Rock Assembly's OSHA Total Case Rate of 7.0 to the Auto manufacturing BLS benchmark of 3.3 (212% of benchmark) across 8 years of Form 300A filings (2016–2024). <a href="/methodology">See methodology</a> for reporting-limitation caveats.
Injury rate over time
Flat Rock Assembly's yearly Total Case Rate, against the 3.3 industry benchmark.
Where Flat Rock Assembly falls in its industry
169 Auto manufacturing establishmentsSafer than 20% of graded establishments in this industry, whose median TCR is 4.0.
Narrower to Michigan alone (the establishments it most directly competes with for workers and contracts): ranked #27 safest of 32 Auto manufacturing employers in Michigan.
Trend analysis for Flat Rock Assembly
Between 2016 and 2024, Flat Rock Assembly's Total Case Rate worsened from 6.4 to 10.5 recordable injuries per 100 full-time workers, a 64% increase across 8 years of OSHA reporting.
The safest year on record was 2021, at a TCR of 5.2, while 2024 saw the highest rate, at 10.5, a spread of 5.3 points between the best and worst reporting years. That's a wide swing relative to the establishment's overall rate, worth checking the year-by-year table below for whether a single severe year is driving the average, rather than a sustained trend.
Summed across those 8 reporting years, Flat Rock Assembly recorded 755 total injuries and illnesses, with no fatalities reported in any of those years. Readers comparing establishments should weigh the 8-year trend above alongside establishment size, since a larger workforce naturally accumulates more raw incidents even at a lower per-100-worker rate.
Verify This Employer with OSHA
The 755 injuries, 372 illnesses shown on this page for Flat Rock Assembly are sourced from its own 8 years of mandatory OSHA Form 300A summaries. Cross-check the underlying establishment record directly against the federal source, name, NAICS classification, recordable case totals, and inspection history are all searchable on OSHA's Establishment-Specific Injury and Illness Data system.
Verify on OSHA Establishment SearchSource: U.S. Department of Labor, OSHA Establishment-Specific Injury and Illness Data. NAICS 336111 - Auto manufacturing.
DART Rate, Transparent Calculation (2024)
What is the DART rate formula?
DART (Days Away, Restricted, or Transferred) is computed by OSHA as incidents × 200,000 ÷ hours worked. The 200,000-hour denominator equals roughly 100 full-time workers, which lets establishments of very different sizes be compared directly.
126 DART incidents × 200,000 ÷ 2,568,108 hours worked = 9.81 DART
Methodology: 29 CFR 1904, OSHA Form 300A recordkeeping
Cross-Validating Context, Establishment vs Industry vs State
| Benchmark | TCR | Source |
|---|---|---|
| Flat Rock Assembly (this establishment) | 7.01 | OSHA ITA Form 300A, 8-year avg |
| Chassis, automobile, manufacturing industry avg | 3.30 | BLS IIF, NAICS 336111 |
| Michigan state avg (all industries) | 4.73 | OSHA ITA, state-level rollup |
Industry benchmarks: Bureau of Labor Statistics, Injuries, Illnesses, and Fatalities (IIF) program
Reportable Incident Timeline
Year-by-year reportable incidents (recordable injuries + illnesses + fatalities) submitted by Flat Rock Assembly to OSHA's Injury Tracking Application. Each row anchors to OSHA's inspection records search where you can pull the underlying inspection case numbers and citations for that establishment-year.
- 2024: 135 reportable incidents · 81 injuries, 54 illnesses, 0 fatalities - OSHA inspection records (case numbers)
- 2023: 133 reportable incidents · 84 injuries, 49 illnesses, 0 fatalities - OSHA inspection records (case numbers)
- 2022: 90 reportable incidents · 61 injuries, 29 illnesses, 0 fatalities - OSHA inspection records (case numbers)
- 2021: 75 reportable incidents · 54 injuries, 21 illnesses, 0 fatalities - OSHA inspection records (case numbers)
- 2020: 85 reportable incidents · 58 injuries, 27 illnesses, 0 fatalities - OSHA inspection records (case numbers)
- 2019: 163 reportable incidents · 121 injuries, 42 illnesses, 0 fatalities - OSHA inspection records (case numbers)
- 2018: 230 reportable incidents · 148 injuries, 82 illnesses, 0 fatalities - OSHA inspection records (case numbers)
- 2016: 216 reportable incidents · 148 injuries, 68 illnesses, 0 fatalities - OSHA inspection records (case numbers)
Source: OSHA Inspection Information System (IMIS) - inspection case-number records
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 |
What this grade means for you
Use this grade as a relative read on Flat Rock Assembly's reported OSHA injury record versus its Auto manufacturing peers, not a verdict on whether any single site is safe today.
- At 212% of the Auto manufacturing benchmark, Flat Rock Assembly reports more injuries than typical peers, ask specifically how the employer is reducing them. Know your rights
- Judge this record against the wider Auto manufacturing sector, where injury rates vary widely, before comparing it in isolation. See the industry
- Grades reflect 2016–2024 filings; check the latest establishment record straight from OSHA, or look up a different employer. Look up another
Safety grades reflect employers' self-reported OSHA Form 300A filings from 2016 to 2024 and can lag current conditions. A grade is not a guarantee that any specific workplace is safe or unsafe today. See our methodology and disclaimer.
Frequently Asked Questions
What is Flat Rock Assembly's safety grade?
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Similar Employers
Matched by safety record across the industry, by workforce size within Michigan, and by nearby establishments in Flat Rock - a different peer set than the category browse links below.
Similar TCR (~7.0)
Similar size (~2,326 workers)
Read our methodology - how this data is sourced, computed, and verified.
Every figure and grade on PlainSafetyScore is computed directly from OSHA's published Injury Tracking Application data and BLS industry benchmarks, no number is typed in by an editor. See our editorial standards & corrections policy, the methodology behind these safety grades, or report a data error. Data current as of 2016-2024 OSHA ITA release.