2. KDI SCHOOL WORKING PAPER SERIES
Case Study of POSCO:
Analysis of its Growth Strategy and Key Success Factors
Seung-Joo Lee & Eun-Hyung Lee
November 2009
Working Paper 09-13
This paper can be downloaded without charge at:
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4. Case Study of POSCO:
Analysis of its Growth Strategy and Key Success Factors
Abstract
POSCO has played a major role in Korea’s economic development by supplying domestic
manufacturers with high-quality, low-cost steel products. Despite its initial disadvantage and
lack of resources such as capital, technology, and raw materials, it has emerged as a world-
class steel maker in a short span of time. This case study aims to explore and analyze the key
success factors of POSCO through examination of the company’s growth and development
process. In particular, it examines the role of government policy, top management leadership,
technology learning and innovation, cost competitiveness and other factors as important
drivers of success. The case also identifies its strategic challenges and key issues for growth
in the future.
JEL Classifications: L61, M10, N80
Key words: Growth strategy, key success factors, steel industry, Korea
5. 1. Introduction
In 2009, at the height of the global financial crisis, Korean steel maker POSCO reported the highest earnings
everinthecompany’shistory.Its2008revenueincreasedby38percentoverthepreviousyeartoKRW30.6trillion,
operating profit rose by 21 percent to KRW 6.5 trillion, and net profit increased by 15 percent to KRW 4.4 trillion
<See Exhibit 1>. While other global steel giants including Arcelor Mittal, Bao Steel and Nippon Steel Corporation
havesufferednetlossesinthefirst-halfof2009,POSCOrecordedaKRW760billioninnetprofitsdespitetheglobal
economicrecession.
POSCO has posted a continual surplus since it first started manufacturing steel in 1973<See Exhibit 2-3>.
Today, it is ranked fourth in terms of steel production <See Exhibit 4>, and it outperformed other global steel
producers in operating margins <See Exhibit 5> and operating rate<See Exhibit 6>. According to World Steel
Dynamics (WSD), POSCO ranked first (2002-2005) and second (2006-2008) in the global competitiveness index
<See Exhibit 8>. The company won perfect scores in seven out of twelve categories of the competitiveness
evaluation<See Exhibit 9>. The company’s market capitalization as of August 2009 was second only to Arcelor
Mittal<SeeExhibit10>.
POSCOhasplayedamajorroleinKorea’seconomicdevelopment.Bysupplyingdomesticmanufacturerswith
high-qualitysteelproductsatprices10to20percentlowerthanimports,ithascontributedtothegrowthandexport
competitiveness of Korea’s major industries such as shipbuilding, automobile, electronics, machinery and
construction.
POSCOhasbeenwidelyrecognizedbyvariousinternationalinstitutions.Thecompanywaschosenasthemost
admiredsteelcompanybyFortune(2006-2009),thebestcompanyinthemetalsandminingsector(2003)andoneof
theForbesGlobal200companies(2008-2009).Itwasalsolistedamongtheworld’s50mostinnovativecompanies
(2003)andthemostadmiredAsiancompany(2007)byBusinessWeek,andintheSAM-DowJonesSustainability
Index,POSCOwasrecognizedasasustainabilityleaderintheindustry(2006-2009)<SeeExhibit11>.
This case study aims to explore and analyze the key success factors of POSCO through examination of the
company’sgrowthanddevelopmentprocess.Inparticular,itattemptstodrawlessonsfromthesuccessstoryofthe
6. steelmaker,whichovercameitsinitialdisadvantageoflimitedresourcessuchascapital,technologyandrawmaterials,
andemergedasagloballycompetitivecorporationinashortspanoftime.
2. Start-upandGrowthStage(1968-1992)
POSCO’skeysuccessfactorsvarydependingonthetimeperiod.Thispaperdividestheperiodintotwostages
toanalyzethekeysuccessfactors. Inthestart-upandgrowthstage(1968-1992),governmentpolicyandsupport,the
leadership of CEO TJ Park, technology acquisition/learning, and cost competitiveness were important drivers of
success.Inthematuritystage(1993-2009),transformationalleadership,technologydevelopment,processinnovation,
andglobalmanagementwereimportantfactorsinthecompany’scontinuousgrowthandsuccess<SeeExhibit12>.
(1) GovernmentPolicyandSupport
Since1948,theKoreangovernmenttriedtoestablishanintegratedsteelmillinKoreatomeettherisingdemand
forsteelandsubstituteforimports.However,Koreafacedextremelytoughconditionstobuildsuchfactories,givenits
limited resources and experience. This reality was reinforced by a 1968 World Bank reportwhichheldanegative
view, saying that the steel mill construction plan Korea had been pushing for was premature. Integrated steel
manufacturingmustsatisfyasetofrequirementstobegloballycompetitive,suchashavingadvancedtechnologies,
massive amount of capital, a domestic market large enough to enable economies of scale, and access to natural
resourcessuchasironoreandcoal.However,noneoftheseexistedinKoreabackinthe1960s.Infact,Koreahadto
borrowcapitalandtechnologyfromoverseas,itsdomesticmarketwassmall,andithadtorelyentirelyonimportsfor
natural resources. From the perspective of advanced steel producing countries, Korea was just a poor nation that
experienced Japanese colonial rule (1910-1945) and the Korean War (1950-1953). It was not surprising that they
belittledKoreaasdreamingtheimpossibledreamofbuildinganintegratedsteelmill.
ThePresidentofKoreaPark,Chung-Hee,however,hadastrongbeliefintheimportanceofthesteelindustryas
thefoundationforthenation’sindustrialdevelopmentandnationalsecurity.Hepersonallymadevariousdiplomatic
effortsattheinternationalleveltosecurecapitalandtechnologyrequiredforsteelmillconstruction.Havingfailedto
obtainloansfromtheU.S.andGermany,PresidentParkmadeabolddecisiontodivertcompensationclaimsfrom
Japan(about$100million)asseedmoneyforthesteelmillconstruction.Astheconstructionplanbegantomaterialize,
the Park administration enacted the Steel Industry Promotion Act in 1970, which enabled various forms of
7. government support for the steel industry, such as provision of low-interest long-term loans, tax breaks, and
infrastructure subsidies such as low-cost supply of factory construction sites, ports, roads, railroads, and water <See
Exhibit13>.Duetosuchgovernmentsupport,POSCOcouldsaveonthecostofrailwayuseby40percent,portuse
by50percent,waterby30percent,andgasby20percent.Itwasalsoabletogenerate80percentofitselectricityuse
bybuildinganin-housepowergenerationfacilities
Despite the financial support from the government, POSCO was established as a corporation under the
CommercialLaw.Theobjectivewastoavoidtheburdenofapublicenterprisesubjecttogovernmentinterventionby
relevant agencies such as the National Assembly and the Board of Audit and Inspection. Considered a private
corporationbylaw,POSCOwasabletoenjoytheautonomyandefficiencyofaprivatecompany.Atthesametime,
by having government ownership of the majority of its shares, the company could have a sound capital base and
securefinancialsupportfromthegovernment.
Government support was extended to the construction of the company’s second steel mill at Gwangyang.
When construction of this second mill was on the government agenda, other potential steel producers such as
Hyundai were more than willing to enter the steel industry. However, the government entrusted the project
management authority to POSCO, in expectation of its superior execution based on the company’s extensive
knowledgeandexperienceinsteelmillconstructionandoperation.
The government started to keep its distance as the steelmaker began to grow rapidly. In fact, the government
made its final investment in 1986, and ended all support upon the abolition of the Steel Industry Promotion Act.
POSCO was first listed in the Korean stock exchange in 1988. From 1998 to 2000, the government gradually
privatized the company by selling its shares in the stock market. Today, POSCO’s shareholders consist mostly of
foreigninvestorsanddomesticinstitutionalinvestors<SeeExhibit14>.
Duringtheperiodfrom1968and1986,thegovernmentinvestedintoPOSCOatotalofKRW220.5billion,
andreceivedbackatotalofKRW3,889.9billionincludingKRW274.4billionincashdividends,andKRW3,615.5
billioninstocksalesandtransfercombined.Toputthesefiguresintoperspective,underthenetpresentvaluemethod,
the government gained a net profit worth KRW 2 trillion ― total revenues of KRW 6 trillion minus the initial
investmentworthKRW4trillion―by2000whenprivatizationwascompleted.
8. (2) LeadershipofCEOTJPark
POSCO’s founder and legendary CEO Park, Tae-Jun played a pivotal role in building the foundation and
corporatecultureofPOSCO.TJPark,beforetakingthehelmatPOSCO,provedhismanagerialacumenbyturninga
deficit-ridden public corporation (Daihan Tungsten) into the black in his first year in 1965. Impressed by TJ Park’s
trackrecordandleadershippotential,PresidentParkChung-Heesawhimastheidealmanagerfortheintegratedsteel
millproject.
TJParkaccomplishedremarkableachievementsthroughoutthecompany’scourseofdevelopment.Undeterred
by the failure to get international loans in 1968, he requested Japan to provide capital and technology support, and
closed the deal by using his personal network. His vision and faith in patriotic service through steel, his attention to
detailsandperfectionism,andhispeople-centeredleadershipencouragedallemployeestounitewithastrongsenseof
commitmentandloyalty.
Some of the key words to describe the leadership of CEO Park Tae-Jun could be “commitment to
excellence based on patriotic mission”. Park stressed a strong commitment to steel mill construction as it borrowed
capitalandtechnologyfromJapanascompensationforitscolonialrule,oftensaying,“Let’sturnrightandjumpinto
theEastSea,incasewefailintheconstructionofthesteelmill.” Thishastakenholdaswhatiscalled“Right-Turn
Spirit” of POSCO, which created a unique corporate culture emphasizing a sense of mission, dedication to goal
achievement,grouployaltyandpersonalsacrifice.
Parkspent mostofhistime workingtogether withPOSCOemployees attheconstructionsite,whichenabled
thecompanytocompleteconstructionofPohangWorksPhase1,2,3and4ina veryshortspanoftime.Evenon
thanksgivingholidays,ChairmanParkwasonthesiteandmadedecisionsrightonthespotifanyproblemsoccurred.
WhentheconstructionofPhase1wasdelayedforthreemonths,thecompanycameupwithemergencyplansand
completedtheprojectonemonthaheadofschedulebyworking24hoursaday.Nonetheless,henevercompromised
onqualityandneverallowedshoddyconstructiontoreducetheconstructionleadtime.Wheninstallingfacilitiesfor
PohangWorksPhase3,Parkdiscoveredmajorflawsinaventilationsystemthatwasalready80percentcompleted.
Muchtoeveryone’ssurprise,heorderedtheemployeestoblowupthesystemandexpeltheconstructioncompany
andtheforeignprojectmanagerincharge.
9. Althoughhemayhavepressedhispeopletoworkwithoutholidays,Parkvaluedtalentmorethananyoneelse.
In1968evenbeforehestartedbuildingthesteelplant,heborrowedKRW2billionfromabankandbuiltresidences
for employees. The residences located near the construction site were clean and comfortable, which helped attract
many talents to Pohang. Another program he emphasized prior to factory construction was employee training.
Many international organizations including KISA said that Korea had few workers with sufficient experience and
knowledge and that the factory operation should be left in the hands of foreign managers. However, Park thought
differently.HewasconvincedthatPOSCOpeopleshouldtaketheinitiativeinoperatingandmanagingthefactories.
Basedonthisfirmconviction,hehadsentPOSCOemployeestoJapan,Australia,Germany,andotherleadingsteel-
producingcountriesaroundtheworldfortechnologytraining,andtheydisseminatedwhattheyhavelearnedoverseas
throughcompanywidetrainingprograms.
(3)TechnologyAcquisitionandLearning
In the initial construction phase, POSCO had to rely on technology experts from Japan Group for the entire
installation process of the first blast furnace in the Pohang steel mill. The Japan Group presented the design and
procurement plan to establish a steel mill capable of producing one million tons of steel. POSCO, lacking the
knowledge and experience to evaluate the business proposal submitted by Japan Group, prepared a double-check
system under which Broken Hills Proprietary Corporation (BHP) from Australia was asked to review the design
drafts and terms of purchase set forth by Japan Group, while Korean experts based in Japan re-evaluated Japan
Group‘sreportswithBHP’s.
POSCOalsodependedonJapanfortheproductionandoperationstechnologieswhenPohangWorksPhase1
got up and running in 1973. Technicians from Japan Group transferred technologies and skills such as inventory
management,productionscheduling,andmaintenancetoPOSCOemployees. Atfirst,POSCOworkersteamedup
with the Japanese experts to learn necessary skills and discussed every single detail about the project until the
construction of Pohang Works Phase 3. Later, however, POSCO workers increasingly built up expertise and
assumedagreaterroleoverJapaneseengineers.
During its facility expansion from 1970 to 1992, construction projects continued one after another as the
companybeganoperatingnewblastfurnaces.Theworkershadtotrainthemselvesfortechnologiestooperateanew
blast furnace, while acquiring cutting-edge technologies to constructandinstallanewformoffurnace. Theshapes
10. andtechnologiesoffurnacesbecamemore sophisticatedandexpandedovertime. UntilthecompletionofPohang
Works Phase 4, POSCO kept learning new technologies by experimenting with new combination of ingredients,
controllingthevolumeofingredients,scheduling,managingtheflowofrawmaterials,andreducingbottlenecks.
POSCOmadetremendousinvestmentsintrainingtheiremployees.Thenumberoftrainedworkerstotaled
about 61,400 from 1968 to 1979, of which 4,200 were trained outside the company, while 1,513 joined overseas
training programs. The investment in employee training is partly reflected in the rapid improvement of labor
productivity. POSCO reduced the number of hours worked per ton of steel shipped from 32.65 in 1975 to 9.62 in
1984,inarelativelyshortamountoftimecomparedtoJapan,whichsawadropfrom10.8hoursin1975to6.5hours
in1984.
POSCOencouragedindividualemployeestoshareknowledgelearnedfromoverseastrainingprogramswith
otherworkersandconductrehearsalstocarryoutgiventasksbeforeactualproduction.Theywereadvisedtorepeat
theirtasksoutloudandputthemintoexecutiontogetabetterpictureofeachother’sworkaspartofanopentraining
program.TheystayedlateatnighttoshareknowledgeandbrushuponwhattheylearnedfromJapanesetechnicians
duringtheday.
POSCO workers did not simply follow the rules and instructions, but were encouraged to actively engage in
productivityandqualityimprovement.ThousandsofvoluntarygroupswithinPOSCOwereformedtoidentifyand
solveproblemsrelatedtoqualityandsafety. Employeeswillinglyparticipatedinthe“proposalsystem”wherethey
madeproposalstoenhancequalityattheworksite.Tominimizedowntime,theyadoptedapreventivemaintenance
system. To stabilize facility management, they implemented a process monitoring system toidentify problems and
resolve them through a thorough review of detailed information. It was not until Phase 3 construction that the
computer-based process monitoring system was adopted, as the manual monitoring system was considered handy
for the workers to absorb technologies and know-how. It was at that time that POSCO went through process
innovationbyadoptingSixSigma,andreducingdefectstothelowestlevelintheworld.
Thanks to such efforts, POSCO was asked by Taiwan-based CSC to teach their workers and transfer
technologies in 1975. In 1986, 13 years after it started production, POSCO took part in a renovation project of
AmericanUSXsteelmillandtaughttheirmanagersandworkersaboutfacilitymanagement,repairandmaintenance.
Today,POSCOisratedasthegloballeaderinsteelmilldesign,constructionandfacilitymanagement.
11. (4) CostCompetitiveness
POSCOsoldproductsatprices10to20percentlowerthanimportsinthedomesticmarket.Thecompanyhad
to keep its domestic prices low to help improve the competitiveness of its customers such as shipbuilding,
automobiles, electronics, construction etc. This is evidenced by the fact that steel prices have risen 3.5 percent on
average vis-à-vis the 4.2 percent growth in producer price index since the 1980s. Therefore, achieving cost
leadershipwascriticalforPOSCO’ssurvivalandcompetitiveness.
WhenPOSCOfirstbeganproductionin1973,itslaborcostwasfarlowerthanitsglobalcompetitors.In1973,
POSCO’slaborcostpertonofsteelshippedwas$7.06,whichwasfarlowerthan$23.83inJapan,$27.06intheU.K.,
$32.86 in Germany, and $37.83 in the U.S. However, with Korea’s economic development, the gap in labor cost
narrowed. during the period from 2002-2006, POSCO’s labor cost averaged US$38.40, higher than China’s Bao
Steel(US$9.38),yetlowerthanArcelorMittal(US$79.70),NSC(US$47.60),andJFE(US$62.20)<SeeExhibit7>.
POSCO’s labor-management relations is considered to be quite amicable compared to other large
manufacturingcompaniesinKorea.In1987,aunionwasorganizedwithinPOSCO.However,itwassoondissolved,
and currently, POSCO runs the Management Consultation Committee that stresses mutual cooperation between
laborandmanagement.Thecompanyiswell-knowninKoreaforitsadvancedemployeewelfaresystem.Massive
investmentinemployeeeducationandtraininghelpedemployeesenhancetheircapabilitiesandbuildloyaltyfortheir
company.
POSCO fully leveraged its status of a late comer and raised efficiency in inventory management of raw
materials and finished goods by designing a U-shaped lay-out that locates processing lines for raw materials and
assembly lines for finished goods close to the port. In particular, POSCO plants are much more efficient than steel
millsinother countriesinthat theyarrangetheentireproductionprocessinonebuildingratherthansegmentingthe
process into separate buildings. Furthermore, the concept of functional connection was already conceived from the
designstageofthefourPohangplants,whichoptimizedtheentiresteelmanufacturingprocessfromtransportationof
rawmaterialstosteelproduction.Thedistancebetweentheblastfurnaceandthepierfromwhichrawmaterialsare
transported was reduced, and Plant 2 and 3 were set up to be closely connected and functionally compatible with
Plant1.Furthermore,itslocationnexttoaportcapableofhandling100,000tonsofsteelfreightwasinstrumentalin
12. reducing the logistics costs in comparison with locations of other steel makers situated inland. In particular, the
Gwangyang Works was modeled on the Pohang Works and built even better with enhanced technology and
accumulatedknow-how.
Ashortenedsteelmillconstructionperiodhelpedsavedirectcostssuchaswagesandindirectcosts.Atthesame
time, this leads to production ahead of schedule, which in turn reduces the cost of production. While setting up the
plants of Pohang Works, POSCO completed 23 facilities out of 26 in total ahead of schedule by as long as over
eleven months. POSCO’s construction cost was about $400 per ton, which was significantly lower than $1,750 in
Brazil, $820 in the U.S., $700 in Europe, and $590 in Japan. Moreover, POSCO was able to reduce costs by
strategically purchasing state-of-the-art equipment through competitive bidding procedures during global economic
recessions.Inparticular,theglobaleconomywashithardbythefirstandsecondoilshocks,whenthecompanybuilt
production lines in Pohang and Gwangyang. However, the hard times benefitedPOSCOasequipmentsuppliers’
bidding prices went down. The company also reduced construction costs by increasingly using local suppliers of
equipmentandmaterials.Localizationrate,whichwasonly12percentintheconstructionofPohangWorksPhase1
and2,shotupto63percentintheconstructionofGwangyangWorksPhase4<SeeExhibit16>.
Smooth operation since the very first year of production and has also been important. POSCO increased its
output-to-inputratefrom0.57inthefirstmonthto1.05inthesecondmonth,1.33inthethirdmonth,and1.45inthe
fourthmonth.Itsoperatingratejumpedfrom44.5percentin1973to114percentin1974.Itsaverageoperatingrate
nowstandsat111percent,thebestamongitsglobalcompetitors.
According to World Steel Dynamics, POSCO’s cold-rolled sheet production cost was 20 percent lower than
Japaneseproducts,21percentlowerthanBritishproducts,26percentlowerthanAmericanproductsand28percent
lower than German products (2002). Another global steel industry research institute, Commodity Research Unit
(CRU)assessedPOSCO’smanufacturingcostofhot-rolledandcold-rolledsheetstobe9percentlowerthanBritish
products,27to31percentlowerthanJapaneseproducts,and28percentlowerthanAmericanproducts.
13. 3.ContinuousInnovationduringtheMaturityPeriod(1992-2009)
(1) TransformationalLeadership
After achieving both quantitative and qualitative growth for 25 years, POSCO experienced a change in top
management leadership with the resignation of Chairman TJ Park in 1992. Efforts were made to fill the leadership
gap. Chairman Chung, Myung-Sik took office in 1993 and started to reform the organization under the ‘New
POSCO Vision.’ In an attempt to streamline the organization that had grown huge in line with its rapid growth,
reform measures were taken to reduce the number of departments from 85 to 76, teams from 349 to 335, and
executives from 49 to 40. There were changes in POSCO’s traditional domestic market-oriented strategy and the
company pursued diversification into telecommunications and expanded its export markets through a
‘ComprehensiveExportStrategy’.
In1994,ChairmanKim,Mahn-JebecamethefirstCEOofPOSCOcomingoutsidethecompany.Inresponse
to the rapid changes in the global steel industry environment, Chairman Kim initiated ‘Green Management’ which
aimedat‘flexibleorganization’,‘democraticmanagement’and‘transparentmanagement’.Thecompanyestablished
a new vision for 2005, redefined its business domain with three key pillars- steel, engineering & construction, and
telecommunications.ThecompanyintroducedtheResponsibilityManagementSystemtoenhancetheaccountability
of line managers, and established the Committee System for senior executives to streamline its decision-making
processandimprovehorizontalcoordinationamongthedepartments.Changesincorporategovernanceweremade
by bringing in outside directors and auditors on the board to enhance corporate transparency and strengthen the
ResponsibilityManagementSystem.
In1998,ChairmanYoo,Sang-Boo,aformerPOSCOexecutive,tookofficewhentheKoreaneconomywasin
adeeprecessionduetotheAsianfinancialcrisis.Toovercomethesluggishdomesticmarket,ChairmanYooinitiated
an aggressive ‘export-drive’ program, and restructured the company’s business portfolio by divesting its
telecommunications business and refocusing on the core business of steel. In response to the privatization and
digitalization trends, he introduced ‘Process Innovation’ to streamline the company’s key processes and develop a
moreflexible,customer-orientedculturethroughoutthecompany.
14. ChairmanLee,Ku-TaekbecamethenewCEOofPOSCOin2003.TodevelopPOSCOasasociallyrespected
and trusted global company, he emphasized the following five management priorities: 1)transparent operation
through management by principles, 2)sustainable growth, 3)competitive advantage through innovation,
4)management valuing human resources, 5)trust-building with stakeholders. As POSCO had already achieved
world-class level in terms of cost and operational performance, the company put more emphasis on developing its
owntechnologiesandhighvalue-addedstrategicproducts.Inaddition,thecompanyactivelypursuedglobalbusiness
opportunities in emerging markets such as China, India, Vietnam, Brazil and Mexico to develop production bases
andsecurerawmaterials.
(2) TechnologyDevelopment
POSCO reinforced its own R&D activities as leading steel companies concerned with “boomerang effect”
refused to transfer advanced technologies to POSCO. The company set up a collaborative R&D network among
industry,academiaandresearchcentersbyestablishingPohangUniversityofScienceandTechnology(POSTECH)
in 1986, the Research Institute of Industrial Science and Technology (RIST) in 1987, and reorganized its R&D
organization in 1996 to accelerate the development of new technologies. In particular, as customers’ needs became
moresophisticatedandmoredemanding,thecompanyhadtochangeitsexistingstrategywhichmainlyfocusedon
producinglow-cost,commoditysteel,anddevelopmore highvalue-addedspecialtyproducts.As a result,sincethe
1990s, production of low value-added hot-rolled products decreased, while the production of high value-added
products such as cold-rolled sheet, steel plates, stainless steel and electrical steel plate continuously increased. <See
Exhibit17>
In order to upgrade its product mix and develop cutting-edge innovative technologies, POSCO selected
automotivesteelsheet,high-endAPIsteelmaterials,400seriesstainlesstechnologyandhigh-endelectricalsteelsheet
as the ‘Four Major Strategic Products’ in 2002. The company also selected the commercialization of FINEX
technologyandStripCastingmethodasthe ‘TwoMajorInnovationProjects.’In2004,high-endhigh-carbonsteel,
TMCPsteelforshipbuilding,high-endtirecordsteel,andCr-Freesurfaceprocessedsteel werenewlyaddedasthe
‘Eight Major Strategic Products’. In 2005 and 2006, high-end stainless, premium wire rod, premium hot and cold-
rolledproductswerenewlyadded.Theshareofstrategicproductsintermsoftotalsalesasof2008was5.9percent,
butitsproductionhascontinuouslyincreasedoverthelastfiveyears<SeeExhibit18>. R&Dinvestmentgrewfrom
KRW161.1billionin1995toKRW203.2billionin2007.
15. Inordertosuccessfullyimplementtheselectedstrategicgoals,POSCOgrantedownershiptotheexecutivesin
charge and ran a cross-functional Mega Y Organization composed of sales, operations and research departments.
POSCO developed a corporate monitoring system to check the progress on technology and product development,
evaluatethecommercialviabilityofpilotprojects,andanalyzeprofitabilitythroughoutthedevelopmentcycle.
ThedevelopmentofFINEXisagoodexampleofPOSCO’srecenttechnologydevelopmentefforts.Compared
to the blast furnace process, the FINEX method enables cost reduction in facility investment as it does not require
cokeorsinterplantsthatpre-processironoreandbituminouscoal.Thismethodcansaverawmaterialcostsasituses
powdered iron ores that are cheaper and more abundant and general coal that is also cheaper. POSCO worked on
new methods that could improve the existing blast furnace technology since 1992. It constructed the FINEX pilot
plant in 1998, and started to develop base technologies ofthe FINEXmethod by test-producing 150 tons a day. In
November1999,POSCOsignedaMutualAgreementontheDevelopmentoftheFINEXTechnologywithVoest
AlpineofAustria.InJanuary2001,itconstructedaFINEXdemoplantthatcouldproduce600,000tonsperannum
and started to successfully operate the plant from May 2003. In May 2007, POSCO built the world’s first FINEX
commercializationfacilitythatcouldproduce1.5milliontonsayear.
Strip Casting is a technology that makes hot coils of 2-6mm by solidifying the hot metal over 1,500 degrees
Celsiusthroughcastingrollsinjust0.2seconds.Withmostofthehotrollingprocessbeingeliminated,thistechnology
reducesfacilityinvestmentandenergycosts,andithasahugeadvantageinmakingsteelwitharelativelyhigherload
onhot-rollingeventhinner.InDecember1991,throughtechnicalcooperationwithDavyDistingtonoftheUKand
through industry-academia cooperation with POSTECH, POSCO developed a 350mm wide strip caster and
conductedover150testcasting.In1994,POSCOsucceededindevelopingastripcasterwithawidthof1,300mmon
its own. By the end of 2000, POSCO conducted more than 500 tests on casting, eventually accumulating a
technologytoproducezero-defect304stainlesssteelsheetcoils.InJune2004,thecompanyconstructedastripcasting
demoplantwithanannualproductioncapacityof600,000tons,andforthefirsttimeintheworld,itprovedthesafety
ofitsprocessbysucceedingincontinuouslycasting500tonsofstainlesssteel.
16. (3) ProcessInnovation
Process Innovation (PI) that started in 1999 was aimed at streamlining the company’s core processes from
rawmaterialpurchasing,productiontocustomerdelivery,andtransformingthecompany’ssystemsandcultureinto
one that is more customer and profit-oriented. POSCO implemented the whole process in a comprehensive and
disciplinedmannerandachievedsignificantcostsavingsandoperationalimprovement<SeeExhibit19>
PI Phase 1: The ISPP (Integrated Sales & Production Planning) that was developed during PI had the following
characteristics.First,SCM(SupplyChainManagement)andERP(EnterpriseResourcePlanning)wereintegratedby
itemsandthisenabledmanagerstoobtainbasicdataonbudgetmanagementofallareas.Second,thebudgetinglead-
time that was shortened to 15 days enabled the conversion of the existing annual budget planning into a quarterly
planning. Third, the system calculated not only the profitability of steel mills and unit plants but also that of each
product line, enabling a more profitability-centered planning. Fourth, more accurate and timely delivery was made
possiblebyimprovingcommunicationwithcustomers.
InordertopromoteERP,POSCOsetupItem,BOM(BillofMaterial)andRoutingdatabases.Itemreferstoall
the materials managed throughout the company. It can be classified into internally produced items and externally
procured items. All materials were codified and task criteria were integrated and standardized. Bill of Material
specifiesallthecomponentsusedintheproductionofacertainitemsuchasrawmaterials,semi-manufacturedgoods,
aswellaserrorratesandusageunits.Routingdefinesstandardmanufacturingprocessandprocessingtimerequiredto
produce certain item, as well as the types and the usage of relevant facilities, labor, electricity, etc. Throughout this
process,alltasksatPOSCOweresavedintostandardizedandquantifiabledatawhicheventuallyservedasabasisfor
thecompany’sintegratedmanagementsystem.
PIPhase1targetedtochangetheavailabletopromise(ATP)lead-timeforhot-rolledcoilsfrom30daysto14
days,thedeliveryfulfillmentratefrom82.7percentto95percent,anddaysofproductinventory10daysto8days.
MostofthetargetsweresuccessfullyachievedandPOSCOmovedontoProcessInnovationPhase2.
PI Phase 2: Since May 2002, all innovation activities started to center around Six Sigma. POSCO’s ISPP was
completed by refreshing the obsolete operation system of steel mills, and the system expanded into other areas that
were excluded during PI Phase 1 such as CRM and SRM. During the three years of Six Sigma implementation,
17. employees learned scientific methods, developed problem-solving abilities and acquired a more customer-oriented
view.Cross-functionalprojectswerelaunchedinordertoeliminateinvisiblebarriersandbuildtrustamongdifferent
functions.InNovember2004,afaster‘Real-timeEnterprise’wasrealizedthroughMES(ManufacturingExecution
System).TheITsystemsof81plantsand47yardsatPohangandGwangyangWorkswereintegrated,aswell.
PI Phase 3: Phase 3 focused on building a corporate culture and way of working that meets global standard of
excellence.Italsofocusedoninnovationactivitiesthatcouldengageeveryone.Therolesandresponsibilitiesofeach
employee were made clear, and an RAI chart was made to check whether those responsibilities were fulfilled.
Measuresweretakentomakeordering,reportingandmeetingsmoreefficient.Inparticular,ordering,reportingand
meetingsbycompanyexecutivesanddepartmentheadswerediagnosedmoreoftentoprovidethemwithfeedback
andtips.In2008,smallteamswereconsolidatedintogroups,andoverlappingfunctionswereintegrated.Inaddition,
cost reduction was further achieved by upgrading and integrating the SCM and the ERP that had been completed
duringPhase2.
(4) GlobalManagement
Duetomarketmaturityandsluggishdomesticmarketgrowth,POSCOhadtolookforinternationalmarketsfor
itscontinuousgrowth.Thepercentageofexporthasbeenincreasingandreached39percentasof2008,withregional
exportstoAsiancountriessuchasChina,IndiaandJapanaccountingformorethan60percent.Assteeldemandfrom
China and Southeast Asian countries was relatively robust, POSCO established production bases in those regions.
POSCOcurrentlyhas4plantsinChinaand4plantsinSoutheastAsia<SeeExhibit20>.
POSCO targeted China’s huge market since the 1990s, and is currently producing products from Dalian
POSCO-CFMCoatedSteelCo.,Ltd.(100,000tonsofcolorsteelsheets)andZhangjiagangPohangStainlessSteel
(500,000tonsofzinccoatedsteelsheetsand500,000tonsofstainlesscold-rolledcoils).Vietnamisanotherstrategic
marketinwhichPOSCOhasthreeproductionfacilities-POSVINA(30,000tonsofcolorsteelsheets),acold-rolled
product plant (1.2 million tons of cold-rolled products), and ASC (30,000 tons of stainless cold-rolled steel sheets).
Thecompanyplanstofurtherincreaseitsinvestmentinthisregion<SeeExhibit21-22>.
18. The CGL (Continuous Galvanizing Line) plant that was completed in Altamira, Mexico in August 2009
galvanizeszinconthecold-rolledcoilsimportedfromKorea.ThecarmanufacturersinMexicoarethemajorclients
ofCGLforautomobilesproducedfromthisplant.Bysupplyingproductsthatcanmanufactureupto400,000carsper
annum,POSCOaimstotargetnotonlytheMexicanmarket,butalsotheUSmarketinthenearfuture.POSCOhas
beenworkingontheconstructionofanintegratedsteelmillinIndia,buthasrecentlyfacedmanydifficultiesingetting
itlaunched.
In order to secure a stable supply of raw materials, POSCO participated in the iron ore and coal mine
developmentofPOSMECinthewesternregionofAustralia,acquiringa20-percentshare.Sincethen,POSCOhas
been actively engaged in acquiring equity stakes in mines around the world such as NAMISA’s iron ore mine in
Brazil,MacArthur’scoalmineinAustralia,andamanganesemineinSouthAfrica.Thecompanyplanstoenhance
itsrawmaterialself-sufficiencyrateto30percentby2012.
In order to increase export to areas with growing demand, POSCO established 8 more SCM (Supply Chain
Management)bases-processingandsalescenters-inChina,SlovakiaandMexico,tobringthetotalnumberofthe
company’sbasesto35.LeveragingthoseSCMbases,POSCOwillstrengthenitscustomerservice,promotethesales
ofitsproductsandmaximizethesynergyeffectofoverseasproductionandsales.Asof2007,POSCOhasinvested
globallyin46companies.Ithasmanagementcontrolrightsin28companiesandhasminorityequityinvestmentsin
18companies.
4. StrategicChallenges
Due to the global financial crisis, growth in global steel demand fell for the first time since 1998. International
steel prices in July 2008 stood at US$1,170 per ton, but dropped to US$606 per ton by December, forcing major
global steelmakers to reduce production. Inline with the global economic stagnation, the domestic steel market has
also witnessed a significant drop. Furthermore, competition is heating up in the domestic market with the entry of
HyundaiSteel.By2010,whenHyundaiSteel’sintegratedsteelmilliscompleted,demandforsteelfromPOSCO’s
major customers such as Hyundai/Kia Motors, Hyundai Heavy Industries, and Hyundai Construction will most
likelydecrease.
19. Globalindustryconsolidationisexpectedtocontinueasglobalsteelcompaniesmergetoachieveeconomiesof
scaleandscope.Itispredictedthatcompetitionamongthe5to6companiesproducingmorethan50milliontonswill
accelerate. Competition for raw materials will also heat up, and regulations regarding climate change and carbon
dioxideemissionswillbecomestronger,creatingmoreuncertaintiesinthemanagementenvironment.
As of March 2009, Chairman Chung, Joon-Yang became the new CEO of POSCO. Despite the global
economicrecessionanduncertaintybothathomeandabroad,ChairmanChunghasannouncedanambitiousvision
forPOSCOofbecomingtheGlobalBig3&GlobalTop3.Heisnowponderinghowtobestachievethegoaland
leadtheworld’stopsteelproducerintothefuture.AlthoughPOSCO’sprofitabilityremainshigh,brightdaysarenot
necessarilyaheadfortheglobalsteelindustry.Inlightofstagnantgrowthinsteeldemand,thepriceofsteelproducts
andrawmaterialscannotbeexpectedtoremainstable.Furthermore,large-scaleChineseplayerswithlowlaborcosts
arerapidlycatchingupwithPOSCO.InJuly2009,Arcelor-MittalproposedtoPOSCOtheestablishmentofajoint
ventureinthestainlesssector.Inthedomesticmarket,potentialM&Aopportunities,such asDaewooConstruction
andDaewooShipbuildingareappearingonthescene.
The new CEO had to reflect on some fundamental strategic questions. What are POSCO’s future growth
strategiesandoptions? Shoulditfocussolelyonsteel,pursueinternationalexpansionorshoulditdiversifyintonew
business areas? If international expansion is the preferred path, where should it build its main production base and
how should it enter the market? Is greenfield investment better than acquisitions or alliances? What are the key
organizationalcapabilitiesthatneedtobedevelopedtoeffectivelycompeteintheglobalmarketplace?
33. < Exhibit 20> Global Network of POSCO
<Source: POSRI 40Years Performance Report>
< Exhibit 21> Global Network of POSCO
2002 2007
Management
Control
Equity
Investment
Management
Control
Equity
Investment
Production Plant 7 3 10 6
SCM 1 5 9 10
Raw Materials 3 1 3 2
Sales 4 - 4 -
Others 1 - 2 -
Total 16 9 28 18
*Excluded Grand-son Companies <Source: POSCO 40 Years Performance Report>
34. < Exhibit 22> Global Network by Regions
China Japan South-
East
Asia
India Eastern
Europe
South.
America
North
America
Australia Africa
Production
Plant
4(3) (1) 4(2) 1 1
SCM 3(5) 2(3) 2(1) 2(1)
Raw
Materials
1 1 1 (2)
Sales 2 1 1
Total 9(8) 1(1) 6(5) 3(1) 2(1) 1 3 1 (2)
<Source: POSCO 40 Years Performance Report>
< Exhibit 23>Average GrowthRate ofSteelConsumptionper Capita(‘97~’06)
<Source:IISI>
37. References
Amsden, A. 1989. “Asia’s Next Giant: South Korea and Late Industrialization” Oxford University
Press.
IBRD. “Korean Economic Review” 1968
Lee & Whang. 1997. “Steel Making at POSCO” Graduate School of Business Stanford
NH Research Center. 2009. POSCO. NH Investments & Securities.
POSCO. 2003. POSCO 35-Year History.
POSRI. 2008. POSCO 40 Years Performance Report.
POSCO. Annual Report. 2001-2008.
POSCO. Fact Book. 2003-2006.
Regani, S. 2004. “POSCO’s Competitive Advantage in the Global Steel Industry” ICFAI Business
School Cases.
Seo, K.K. 1997. “The Steel King” Simon & Schuster. U.S.
World Steel Dynamics. 2008. Core Report D. Financial Dynamics of International Steelmakers.
Yoon, S M. 2000. “A Study on the Institution Building Strategies of POSCO” Doctoral Dissertation.
Department of Public Administration. Graduate School. Chung-Ang University.
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Jae Kyun Shin
Why Do Megacities Coexist with Small Towns? Historical Dependence in the
Evolution of Urban Systems
Working
Paper
08-26 Jinsoo LEE When Business Groups Employ Analysts: Are They Biased?
Working
Paper
08-27 Cheol S. EUN
Jinsoo LEE
Mean-Variance Convergence Around the World
Working
Paper
08-28 Seongwuk MOON How Does Job Design Affect Productivity and Earnings?
Implications of the Organization of Production
Working
Paper
08-29 Jaeun SHIN Smoking, Time Preference and Educational Outcomes
Working
Paper
08-30 Dong Young KIM Reap the Benefits of the Latecomer:
From the story of a political, cultural, and social movement of ADR in US
Working
Paper
08-31 Ji Hong KIM Economic Crisis Management in Korea: 1998 & 2008
Working
Paper
08-32 Dong-Young KIM Civility or Creativity?: Application of Dispute Systems Design (DSD) to Korean
Public Controversies on Waste Incinerators
Working
Paper
08-33 Ki-Eun RHEE Welfare Effects of Behavior-Based Price Discrimination
Working
Paper
08-34 Ji Hong KIM State Owned Enterprise Reform
Working
Paper
09-01 Yu Sang CHANG Making Strategic Short-term Cost Estimation by Annualized Experience Curve
Working
Paper
09-02 Dong Young KIM When Conflict Management is Institutionalized:
A Review of the Executive Order 19886 and government practice
Working
Paper
09-03 Man Cho Managing Mortgage Credit Risk:
What went wrong with the subprime and Alt-A markets?
* The above papers are available at KDI School Website <http://www.kdischool.ac.kr/new/eng/faculty/working.jsp>.
You may get additional copy of the documents by downloading it using the Acrobat Reader.
45. Working Paper Series
Category Serial # Author Title
Working
Paper
09-04 Tae H. Choi Business Ethics, Cost of Capital, and Valuation
Working
Paper
09-05 Woochan KIM
Woojin KIM
Hyung-Seok KIM
What makes firms issue death spirals? A control enhancing story
Working
Paper
09-06 Yu Sang CHANG
Seung Jin BAEK
Limit to Improvement: Myth or Reality? Empirical Analysis of Historical
Improvement on Three Technologies Influential in the Evolution of Civilization
Working
Paper
09-07 Ji Hong KIM G20: Global Imbalance and Financial Crisis
Working
Paper
09-08 Ji Hong KIM National Competitiveness in the Globalized Era
Working
Paper
09-09 Hao Jiang ,
Woochan Kim ,
Ramesh K. S. Rao
Contract Heterogeneity, Operating Shortfalls, and Corporate Cash Holdings
Working
Paper
09-10 Man Cho Home Price Cycles: A Tale of Two Countries
Working
Paper
09-11 Dongcul CHO The Republic of Korea’s Economy in the Swirl of Global Crisis
Working
Paper
09-12 Dongcul CHO House Prices in ASEAN+3: Recent Trends and Inter-Dependence
Working
Paper
09-13 Seung-Joo LEE
Eun-Hyung LEE
Case Study of POSCO -
Analysis of its Growth Strategy and Key Success Factors
* The above papers are available at KDI School Website <http://www.kdischool.ac.kr/new/eng/faculty/working.jsp>.
You may get additional copy of the documents by downloading it using the Acrobat Reader.