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FINAL REPORT v

June 2005


























Report Prepared for The National Coil Coating Association by
Thomas Associates, Inc. Statistics Department

NCCA Safety Data for 2004
FINAL REPORT

NCCA Safety Data for 2004
Thomas Associates, Inc.
Final Report, June 2005
Statistics Department

i



TABLE OF CONTENTS



Introduction...........................................................................................................................................................................1

Methodology.........................................................................................................................................................................1

How to Read this Report......................................................................................................................................................1-3

Executive Summary ..............................................................................................................................................................4-6

Injury/Illness Ratios ............................................................................................................................................................7

Safety Data for 2001-2004 Results .......................................................................................................................................8-23



Appendix A: Solicitation Letter


Appendix B: Safety Data for 2001-2004 Survey


Appendix C: 2004 Participating Comp anies































NCCA Safety Data for 2004
FINAL REPORT

NCCA Safety Data for 2004
Thomas Associates, Inc.
Final Report, June 2005




Statistics Department

1

Introduction

In an effort to provide the NCCA membership with useful and instructive data, the NCCA Government
Relations Committee (now the Environmental, Health, & Safety Committee) initiated the Safety Data
Collection Project in 1997. The main purpose of this project is to track employee injury and illness rates for
active member companies on an annual basis, so that the rates can be used as a safety benchmark. Currently,
OSHA and the National Safety Council do not provide data exclusively on coil coaters, making it difficult for a
coil coater to determine how their employee accident history relates to the accident history of other coil
coaters.

Methodology

This year, NCCA asked active member companies operating within the U.S. to submit safety data for 2004,
2003, 2002, and 2001 for comparative purposes. It is important to note that non-U.S. companies are unable to
provide OSHA data; therefore, only U.S. member companies were able to provide the OSHA 300 form for
2003 and 2004 and the OSHA 200 form(s) for 2001-2002. Company representatives were asked to provide
some additional information regarding the number of employees, hours worked at their facility and descriptive
information for each accident or injury which resulted in lost time away from work. This procedure is similar
to the one conducted in the initial year of the study. Further, member companies were asked to list actions
taken to remedy the problem or cause of each accident or injury and to provide general information regarding
their plant's safety program.

For reference purposes, a copy of an OSHA 300 form, the solicitation letter and the Safety Data 2001-2004
Survey are contained in Appendix A, B, and C, respectively. A list of participating companies that submitted
data for this report appears in Appendix D.

For questions regarding data collection or findings of this report, please contact Christopher Johnson of
Thomas Associates, Inc. located in Cleveland, Ohio.

How to Read this Report

Ratios
All ratios included in this report have been derived using the data submitted by participating companies. All
individual company ratios were computed first, and then means, medians and quartiles were computed. The
number of responses for which means, medians and quartiles are based is also reported.

Percentages, Means, Medians and Quartiles
Percentages are derived by dividing the number of responses per category by the total number of the responses
to the survey. Percentages are shown in whole percents. It is important to note that multiple responses were
allowed for some survey questions; therefore, some percentages will not total to 100%.

Means (averages) were derived by adding the ratios and dividing by the total number of responses. Medians
represent the midpoint below which 50% of the ratios lie when the values are arranged in order of magnitude.
The Lower Quartile (25th percentile) represents the point below which 25% of the ratios lie; and the Upper
Quartile (75th percentile) represents the point below which 75% of the ratios lie when the values are arranged
in order of magnitude.
NCCA Safety Data for 2004
FINAL REPORT

NCCA Safety Data for 2004
Thomas Associates, Inc.
Final Report, June 2005




Statistics Department

2

How to Read this Report (continued)

Computations
Listed below are the computations used to derive the ratios shown in this report. The data were derived from
the OSHA 300 form and the total number of hours worked (plant and office hours) during the period submitted
for 2004, 2003, 2002, and 2001. In order to ensure accurate benchmarking, data from the OSHA 200 forms
was derived and then converted to reflect the information requested from the OSHA 300 form. This year, ratios
are listed in one section of the report using injury and illness data combined.

u
u

Injury/Illness Incidence Rate [(number of injuries and illnesses x 200,000)/total number of hours
worked during the period]
for example, for injuries/illnesses: [s</i>um of column M1, M2, M3, M4 and M5 from OSHA 300 form x
200,000/total number of hours worked]

u
u

Lost Workdays Incidence Rate [(number of lost workdays x 200,000)/total number of hours worked
during the period]
for example, for injuries/illnesses: [sum of columns K and L of OSHA 300 x 200,000/total number of
hours worked]

u
u

Average Lost Workdays per Total Lost Workday Cases [total lost workdays/total lost workday
cases]
for example, for injuries/illnesses: [sum of columns K and L/sum of columns H and I of OSHA 300]

u
u

Average Days Away from Work [total days away from work/total cases involving days away from
work]
for example, for injuries/illnesses: [sum of column L/sum of column H of OSHA 300 form]

u
u

Lost Workday Cases [(number of lost workday cases x 200,000)/total number of hours worked during the
period] for example, for injuries/illnesses: [sum of columns H and I of OSHA 300 x 200,000/total number
of hours worked]

u
u

No Lost Time Cases [(number of no lost time cases x 200,000)/total number of hours worked during the
period]
for example, for injuries/illnesses: [sum of column J of OSHA 300 x 200,000/total number of hours
worked]











NCCA Safety Data for 2004
FINAL REPORT

NCCA Safety Data for 2004
Thomas Associates, Inc.
Final Report, June 2005




Statistics Department

3
How to Read this Report (continued)

Number of injuries:
u
u

Column Ml of OSHA 300 form

Number of illnesses:
u
u

Columns M2, M3, M4 and M5 of OSHA 300

Number of injuries in addition to illnesses:
u
u

Columns M1, M2, M3, M4 and M5 of OSHA 300 form


Number of lost workdays due to injuries and illnesses:
u
u

Columns K and L of OSHA 300 form

Lost workday cases due to injuries and illnesses:
u
u

Columns H and I of OSHA 300 form

Days away from work due to injuries and illnesses:
u
u

Column L of OSHA 300 form

Cases involving days away from work due to injuries and illnesses:
u
u

Column H of OSHA 300 form

Number of no lost time cases due to injuries and illnesses:
u
u

Column J of OSHA 300 form
*Please note not all companies submitted data for all years. The total number of responses on which
data is based is noted in the column identified as "Number of Responses."




















NCCA Safety Data for 2004
FINAL REPORT

NCCA Safety Data for 2004
Thomas Associates, Inc.
Final Report, June 2005




Statistics Department

4
Executive Summary






Trends
In 2000, participating coil coaters reported the highest average injury/illness incidence rate (9.6) compared
to the remaining four reporting years (see Graph I. Below). The lowest average injury/illness incidence
rate (7.5) was reported in 2001. There was a steady increase in the average in