Since 2014, sales of products combined with Solution Marketing have tripled, and sales of POSCO’s World Premium Products (WPP) have increased by 56 percent.

It Wasn’t Always Smooth Sailing

When the 2008 global financial crisis hit, the global economy as a whole suffered. The steel industry experienced stagnant growth, even in its subsequent recovery. From 2012 to 2016, annual steel sales remained fixed at 35 million tons.

The 2008 Financial Crisis was felt in markets all over the world. (Source: South China Morning Post)

The main culprit for the slow recovery was overproduction, mostly from the heavily-subsidized Chinese steel industry. Between 2000 and 2014, steel production doubled from 800 million to 1.6 billion tons, exceeding the global demand for steel by 100 million tons.

As a result, steel markets around the world saw prices falling, layoffs and steel mill closures.

SEE ALSO: Asian Steel Watch: Megatrends Shaping the Future of the Steel Industry

A Strategy for Success

In order to stay competitive in a stagnant market, POSCO made the decision to focus on Solution Marketing and the sales of its World Premium Products (WPP) such as POSCO GIGA STEEL for cars and PosMAC for solar panels.

Solution Marketing involves hyper-customization for POSCO’s partners to deliver optimal material solutions for their products. Some notable projects this year have been with automakers GM Korea and Ssangyong Motors for the launch of their new models made of POSCO GIGA STEEL. POSCO gave them full support from development and R&D to testing and post-production evaluations, redefining the role of a steel supplier.

GM Korea and POSCO worked together to incorporate POSCO GIGA STEEL into the 2017 All New Chevy Cruze. (Source: GM Korea)

As a result, POSCO’s operating profit margin (individual basis) was 10.8 percent in 2016, making it one of the highest performing steel companies in the world. Its recovery and growth continued into 2017.

SEE ALSO: 6 Reasons Why POSCO GIGA STEEL is Ideal for Automakers

Cultivating the Industry

Following its continued success with Solution Marketing, POSCO is now determined to share its insights and technology with up and coming small and medium-sized enterprises (SMEs). POSCO has completed 32 shared-growth projects through which they work with SMEs to develop ways to cut costs, improve the quality of their work, provide financial assistance and education and training.

One of the most recent projects for shared growth is a collaborative business model called “System Construction” that provides a framework for effective technical cooperation among POSCO’s partners in the construction industry. The model was developed jointly with NI Steel and entails systemizing composite materials such as beams, floor decks, exterior panels and roofing materials, all based on joint R&D from both parties.

Under System Construction, workers from various sectors come together for joint development.

POSCO is continuing its efforts to advance its competitiveness by providing material and technical solutions to its partners, and along the way, fostering the growth of SMEs in various industries to ensure a more stable and robust economy.

Since the early 20th century, car manufacturers have realized the importance of using specific steel for specific purposes. Henry Souther of the New York Times reported in 1909, “The secret of the use of steel is to put the right steel in the right place.” Until fairly recently, automotive steel mostly consisted of weaker mild steels that were affordable and easy to form into parts, but innovations in advanced high-strength steels (AHSS) have given automakers more options when designing vehicles.

Today’s automakers and parts manufacturers must consider several properties of the steel they are using: formability, crashworthiness, and durability. Each plays an important role in how the car is made and how the car performs over time and during impact. Below we take a look at these criteria and why each is important for manufacturers when designing a car and its parts.

Formability in Manufacturing

Formability is a key aspect to any automotive material. If a part cannot be made, it cannot be used. Typically, to make steel stronger, automakers had to make sacrifices in weight and formability, and if manufacturers needed a material with more ductility they were forced to give up strength.

The first generation of advanced high-strength steels (AHSS) increased strength while decreasing weight, giving automakers the opportunity to use thinner steel sheets. However, as the steel became stronger it lost formability, making it difficult to mold into parts.

POSCO GIGA STEEL is formable so that it can be shaped into complex parts.

Development of the second generation of AHSS focused on improving formability and elongation; however, its commercial use was limited due to its high cost and tendency to produce delayed cracking at room temperature.

With the new third-generation AHSS, like POSCO GIGA STEEL, steel producers have been able to bridge those gaps by producing steel that is formable, strong, and durable.  

While the average car built in 1975 utilized just 3.6% medium and high strength steels, by 2007 that percentage had increased by more than 230% in large part because the practical uses of AHSS have expanded.

Crashworthiness is Key for Safety

Crashworthiness is one of the most important elements to consider when designing automobiles because it is directly linked to the safety of passengers. The crashworthiness of a car is affected by many things including its structural build, safety devices, and materials.

While crash tests of full vehicles are often performed when developing a new car, crash tests of automotive parts are not carried out as often. To bridge this gap, POSCO developed its own crash test simulation for auto parts using high-speed compression and bending.

Crashworthiness criteria such as energy absorption & fracture, collapse mode, reaction force, and mean load is evaluated to provide reference data for car design. With these tests, POSCO is able to provide dynamic material data to its customers in order to propose the most appropriate steel solutions that maximize safety for passengers.

SsangYong Motor designed the new G4 Rexton SUV with a body frame that contains 63% POSCO GIGA STEEL. This is the highest ratio ever achieved in a body frame design and helps ensure significant levels of strength and safety for consumers. In the video below, watch as the SUV goes through various safety tests showing its crashworthiness and durability.

Durability to Prevent Fatigue Failure

The durability of parts is a critical factor to consider in vehicle design as their complicated components are subject to a wide array of complex stresses. In cars, material fatigue due to repeated mechanical loading can lead to the damage of critical components. Also, as vehicles are mobile machines, they are subject to even more unpredictable degrees of loading that can amplify the effects of fatigue on their parts. Moreover, because fatigue failure is often abrupt and difficult to detect, material providers must work to improve durability and ensure longer fatigue life.

“90% of the failures which occur in engineering components can be attributed to fatigue.”
– TR Gurney, Fatigue of Welded Structures

POSCO works with customers to provide accurate durability analysis for each of its products. Through extensive testing with various steel types, specimen shapes, and welding conditions, POSCO is able to provide in-depth testing results requested by customers.

POSCO also works with customers through its Solution Marketing 2.0 program that helps optimize the design and production process of each part – helping ensure that durability performance meets the customer’s needs.

POSCO GIGA STEEL provides automakers with durability to protect against fatigue failure.

Parts that require higher durability such as the CTBA (Coupled Torsion Beam Axle), wheel, engine cradle, lower control arm and stabilizer bar are interlinked with the fatigue data of POSCO steel. This provides the results of the durability analysis in order to suggest the most appropriate steel type for the manufacturer. Furthermore, POSCO supports joint research with customers for the design, manufacturing, and durability evaluations of its parts. POSCO also analyzes the causes of fatigue failure through SEM imaging of fatigue fracture surfaces, measurements of surface roughness, and measurements of strain rate and residual stress.

Today’s automakers must consider these properties during the design and manufacturing stages in order to find the right steel for each component. POSCO is committed to working with its automotive customers to ensure that the right steel solution is used for the right part – helping to find the right balance between formability, crashworthiness, and fatigue life.

High-Quality Steel Products Keep POSCO Competitive in China

In China, several factors have led to more difficult market conditions. Can you tell us about what it is that POSCO is doing to stay competitive in China? How do POSCO’s steel products compare to those from other companies?

Kim Huyn Ah: POSCO has done several things to remain competitive. First, we have focused our attention on creating high-quality World Premium Products. As you know, there is a lot of low-priced, low-quality steel, but our World Premium Products stand out because we are able to make them consistently and without defects. Secondly, POSCO has positioned itself near other key industries. For example, our machining centers in China are located near other large international car manufacturers like GM and Volkswagen. So, even when market conditions go south, there is always stable demand simply due to the geographic proximity.

Yuan Feng: In mid-2015, our production output of World Premium Products was around 30%. By 2016 that had increased to 49%, and as of January 2017, our total output consists of 55% World Premium Products. As Huyn Ah said, other companies can make similar products, but no one can do it at our speed and consistency. Our customers rely on that.

Wang De Hui: Because of the overcapacity of steel, things were difficult for a while, but they are getting better. We get our raw materials from HQ, and because our raw materials are better we can provide better products. And actually, the abundance of low price, low quality steel ended up creating more demand for our advanced, high-quality steel products.

We are committed to maintaining higher quality products. Each year we analyze the steel to make sure the raw materials and production processes are better, more advanced, and with fewer impurities. I know the difference between our materials and our competitors. What we get from Korea is just better.

Better Customer Service with Solution Marketing 2.0

In addition to producing high-quality steel, how does POSCO stand compared to other steel companies? What is it doing to keep customers satisfied?

Kim Huyn Ah explains the importance of POSCO’s high-quality products in China’s market

Kim Huyn Ah: At POSCO, when questions come up, or if a problem occurs, we do our best to find a solution as soon as possible. Through POSCO’s Solution Marketing 2.0, we provide our customers the tools they need to maximize convenience and efficiency in utilizing high-quality steel.  Solution Marketing 2.0 is practiced under three strategies: digital solution marketing based on advanced IT technology; innovative solution marketing that focuses on speed, value and quality; and tailored solutions that provide comprehensive support for each customer. This process helps our customers understand the balance between a product’s features, price, and long-term benefits.

Also, we work hard to provide products to clients on time and on schedule. It is one of the most basic parts of our job, but oftentimes one of the most difficult to control due to floods, typhoons, or other things that are out of our control. Customers demand more, so at POSCO CSPC we have made production systems management a priority so that we can deliver our steel products on time. Because of these improvements, we have been able to meet delivery times more effectively than other steel companies in the area.

Yuan Feng: Huyn Ah really touched on a lot of the important points for us, but I would like to add that POSCO now has an entire department dedicated to service. Now we are able to listen to customers more effectively and respond to their questions and feedback more quickly. We do our best to solve problems as quickly as possible.

Wang De Hui: The Chinese steel market has grown very quickly. Because POSCO is almost 50 years old, we have a better understanding of service and quality. That being said, our competitors in China are learning fast. We must continue to adapt and be competitive. Last year, POSCO set up a Solutions Marketing program to promote high-quality products and customized solutions. Our customers really appreciated that we had higher quality products and were willing to work with them for individualized solutions.

POSCO Fosters Employee Development

All of you are in Korea participating in POSCO’s Global Mobility Program (GMP) where you are able to collaborate with other POSCO employees from around the world while developing new skills at HQ. As part of the management team in China, how has POSCO helped you grow in your career?

Kim Huyn Ah: It is helpful for me to take part in the Global Mobility Program. Seeing HQ and how they work helps us understand the full system process better. Also, as a Korean, I am often in the middle between HQ and our local Chinese office. It can be difficult to understand communicate to both sides effectively. But POSCO has supported me in my career and this experience will help me have a better understanding of the work process in Korea.

Yuan Feng explains the significance of being able to get training at POSCO HQ. His work in maintenance is critical to maintaining smoothly running factories that deliver POSCO’s steel products on time and without defect.

Yuan Feng: I joined the Global Mobility Program because I wanted to learn more. My department is new; it was just formed last year so I want to see more about POSCO and how it works. I think the GMP gives me the opportunity to develop more as an employee, but also in other ways as well. For example, I can have the chance to work with people from other countries and learn about their cultures as well. When I first started, I had to work with some people from Indonesia. We both had a bit of trouble understanding each other, which is natural. However, after we learned about each other’s cultural backgrounds we could understand each other much better.

I will be in Korea for 6 months. During that time I want to create a new system for our Maintenance Department so that it can be more stable and strong. In addition, because it is a new department there needs to be a systematized program for development. We have done well since last year, but we have bigger goals and we want to do more.

Wang De Hui: This is an exciting opportunity for me. I want to improve my skills and do more with POSCO. Being a quality control specialist, I’m responsible for collecting data and measuring performance and customer choice. It is important for me to know how these things are done at HQ so we can improve our efforts in China.

POSCO is Tops in CSR in China

POSCO has won many awards around the world for its CSR work. In particular, it recently won one of the top awards for Corporate CSR work in China. Have you participated in any of POSCO’s CSR events? What effect do those activities have on the community?

Kim Huyn Ah: At POSCO CSPC we have a CSR department that organizes several activities. We have events to plant trees, visit nursing homes, and help out at homes for disabled children. My most memorable experience was when I visited a home for disabled children. When we visit, they greet us so warmly and show so much gratitude.

Wang De Hui has seen the impact of POSCO China’s CSR work

Yuan Feng: At our office, we participate in several CSR activities. We help out with environmental initiatives and with the local communities around the factory as well. We support 3-4 families regularly with supplies and help them with simple things like painting their houses. We sometimes go on trips with them. In the beginning, we would simply donate money, but after seeing the benefit to the communities, and for the staff as well, we are becoming more and more active with CSR activities.

Wang De Hui: At POSCO Qingdao, we organize an event every month. It is well attended by our staff as even our general manager and department managers go. I’m glad we do things like this and I enjoy participating. We mainly go to help out at public nursing homes and schools for the deaf. We also raise money to buy basic needs, such as food, clothes and home appliances. Activities like this have given POSCO a good reputation in the local communities, which is important.

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Take a look at three of the ways transportation is restructuring itself for faster, more sustainable travel. Some are closer to realization than others, but all of them are changing the way we think about movement. When realized, all of these ideas will have an impact far beyond what we can see now.

The Hyperloop – Fast & Frictionless

An Idea by Elon Musk

In 2013, Elon Musk came up with the idea for the Hyperloop as he grew frustrated with the high-speed rail being developed in California at that time. He called it “both one of the most expensive per mile and one of the slowest in the world.” Musk said, “It would be great to have an alternative to flying or driving, but obviously only if it is actually better than flying or driving.”

He imagined capsules, zooming by at speeds faster than any train or plane, that would allow him to get to San Francisco from LA in 35 minutes. The basic concept was that the capsules would float through partially evacuated steel tubes propelled by fans and electromagnets. Because there would be less friction from air and rails, there could be significant increases in speed and durability, while decreasing reliance on fuel at the same time.

Workers install Hyperloop’s stator blocks at our test and development site in North Las Vegas. (Photo courtesy of Hyperloop One)

Because Musk was so involved transforming the space industry with SpaceX, the auto industry with Tesla, and the energy industry with SolarCity, he did not seem to have much time for Hyperloop. So, he developed a 58-page outline of his ideas and left it to others to develop. And they have.

Hyperloop One Unveils Testing Site

To fulfill this improbable dream, a handful of startups have stepped in – one of them being California-based Hyperloop Technologies. They have been building a test site, called DevLoop, 30 minutes outside of Las Vegas in the Nevada desert that was unveiled last week to the public. According to their press release, DevLoop is a 500-meter full-scale Hyperloop test structure weighing over one million kilograms. The Hyperloop One tube measures 3.3 meters in diameter and they are expected to perform their first full test sometime in the first half of 2017.

Hyperloop unveiled its first test site, the DevLoop on March 7. Later this year, they will run their first test of the Hyperloop. (Photo courtesy of Hyperloop One)

In November, Hyperloop Tech signed an agreement with the Dubai Roads and Transport Authority to evaluate building a Hyperloop between Dubai and Abu Dhabi. When completed, a commute that once took several hours will take just 12 minutes.

All parties involved realize the costs are going to be high. Creating a new form of transportation infrastructure is not simple and building large steel semi-vacuum tubes over ground (or under) is technologically difficult requiring trained engineers and highly skilled workers. To offset this, Hyperloop Tech is focusing some of its energy in attracting industrial freight clients.

The Future of Freight

One of Hyperloop Tech’s Transportation Economists, Dapeng Zhang, recently presented on transformational freight explaining that their “vision at Hyperloop One is to connect cities into mega-regions, and turn metro areas into metro stops. This will inevitably improve the efficiency of freight supply chains. By connecting two distant metros, Hyperloop One creates a geographical cluster which could help reduce inventory costs, promote even more just-in-time strategies, and expand same-day delivery service areas.”

A Hyperloop steel tube awaits entry into the tube processing building, where they are painted and prepped for use. (Photo courtesy of Hyperloop One)

Whether or not this is completely feasible is still up for debate, but it is exciting to see the strides being made in this type of supersonic transportation technology. Other developments such as electric cars, autonomous vehicles, and SkyTran (below) will help us move short distances, but ideas like the Hyperloop are needed to connect the larger metropolitan areas.

SkyTran – Personal Rapid Transit

Apart from the Hyperloop and autonomous driving technology, other personal mobility developments are being made. One of those is SkyTran, a company working to develop a personal rapid transit system that carries people in autonomous pods. Located near Mountain View, California, SkyTran has focused its efforts on relieving congestion in cities by creating a system that rides on an elevated monorail. It is both quick and efficient, and unlike the Hyperloop, it is nearing completion with plans to open in Israel, Nigeria, and France.

This concept image shows a drop-off point for one of SkyTran’s capsules. (Photo courtesy of SkyTran)

Using what is called maglev technology (magnetic levitation), the SkyTran uses electromagnets (similar in concept to the Hyperloop) to propel itself forward (up to 155 mph) while using little to no electricity. SkyTran says that when the pod reaches 10 mph, it can continue to glide and accelerate without any extra power. SkyTran’s CEO says the pods can on the same amount of electricity as two hair dryers.

SkyTran capsules are elevated above the city streets avoiding traffic and giving them the freedom to move at high speeds. (Photo courtesy of SkyTran)

In addition to being highly efficient to operate, SkyTran benefits in its low upfront costs. Unlike the Hyperloop, which requires rather large infrastructure and maintenance costs to ensure proper functionality of the pipe’s vacuum and propulsion system, SkyTran is projected to be a much more economic option. Because the system is set up above the streets, its footprint is small – requiring only an 18-inch steel pole to hold the steel and aluminum capsules.

The company estimates that it will only cost about USD 13 million per mile to build, compared to a subway system that can cost around USD 160 million for the same distance. Because of the low upfront costs, SkyTran believes that malls, hotels, and other private businesses will want to build their own offshoot lines – not only for their customers but because it will be profitable.

POSCO’s Advanced Auto Steel in Future Cars

Autonomous, connected, electric. These are the common buzzwords that come to mind when we think about future trends in personal transportation. At CES earlier this year, seemingly everyone had their own solution to made driving cars more connected and safer, and with less human involvement.

Nissan and BMW unveiled plans to use Microsoft’s personal assistant technology, Cortana, with their cars. Honda became the first major manufacturer to develop an electric concept car specifically designed for ride-sharing. And as for self-driving cars – Nissan announced it would bring autonomous driving support to its Leaf electric car, Hyundai introduced one that would be affordable enough for the masses, and Audi announced a partnership with Nvidia to bring self-driving cars to market by 2020.

At the 2016 North American International Auto Show (NAIAS), POSCO showcased its advanced automotive steel products that are both strong and lightweight, making them uniquely suited for the electric cars of the future.

The weight of POSCO’s advanced auto steel is about 26.4 percent lighter compared to that used in most mid-sized vehicles. But despite being lighter, it received the highest level possible ratings from Europe and North America’s automobile collision evaluation Institute, Euro NCAP and IIHS.

In addition, the Life Cycle Assessment (LCA), which measures the amount of CO2 discharged throughout the entire life cycle from material production to recycling, showed that emissions from the internal combustion engine body were 50 percent lower. Electric car emissions were also decreased by about 9 percent.

POSCO’s advanced auto steel is uniquely developed to be lighter and stronger for the cars of the future

The displayed products included the new PosM Steel and hot press forming steel (HPF). PosM Steel is a “dream material” for car manufacturers because it is five times stronger than other steel in terms of machinability while also having an impact absorption of up to 100 kg per mm². While many steelmakers have been developing PosM Steel type steel, it has never been produced on a commercial scale before. In addition, POSCO’s HPF steel is stronger than many other steel alloys making it a good solution for manufacturers looking to improve car safety.

POSCO currently supplies advanced auto steel sheets to car and component manufacturers, including Toyota, Volkswagen, and GM. POSCO has 10 automobile production plants and 24 machining centers around the globe. In addition to providing its World Premium Products, POSCO also provides Solution Marketing services that offer customized technologies developed in-house (such as welding and molding) that are customized to fit a customer’s unique needs depending on the product and manufacturing process.

Innovations in the transportation industry require big ideas, big investments, and new technological advancements. Right now, all of these seem to be coming together for what is expected to be some big changes. If the investors at Hyperloop and SkyTran have their way, pretty soon we will be able to travel across Europe on a Hyperloop, transfer to a SkyTran, and arrive in our hotel in less than an hour.

*Cover photo courtesy of Hyperloop One.