Richard,
Good point, but consider this. A majority of injuries and even deaths ( the actual subject here) can easily be prevented by just following already pre-existing guidelines.
Now under OSHA Form 200 requirements a reportable injury does not necessarily mean it was horrendous in nature. If, for whatever reason, an employer modifies an employees job to compensate for a minor injury not requiring medical attention, lets say something like dirt in the eye and the employee instead of being a mechanic was given clerical duties for the rest of the day, the injury is reportable on the OSHA record.
Now going beyond that lets say the employee had to see a physician for the substance in the eye. The initial visit and a couple of follow ups can go into the thousands of dollars ( we had one hit $9000 for dirt in the eye). The cost of us complying with the law and "our own written and approved safety rules" was only $2.50 for a pair of safety glasses.
Now if the employee had lost the eye, we (the employer) would have had to report the case by phone to OSHA. The corresponding potential penalty for this 1 single violation of law and our own policy is $70000.
It seems to me conforming to requirements is cheaper regardless.