In the steelmaking field, we continued to develop key technologies
to improve convertor productivity and durability. In recent years,
we have improved our dynamic refractory brick repair process and
slag control methods, developed a zero-downtime refractory reconstruction
process, and installed an N2 splash-coating facility. These ongoing
advances at the Pohang No. 2 Steelmaking Plant have produced an
industry-leading convertor lifespan performance, rising from 5,967
heats in 2001 to 7,218 heats in 2003. Together, these advances enabled
us to raise our 2003 crude steel output by 834,000 tons to 28,900,000
tons.
Maintaining Excellence
In 2003, the second full year since we launched our Maximo computerized
maintenance management system in 2001, facility downtime fell 47.9%
at Pohang and 9.9% at Gwangyang, while planning accuracy rose by
23.2% and 27%, respectively. Ongoing facility upgrades and systematic
inspections extended our regular hot-rolling mill shutdown cycle
from four weeks to five weeks, eliminated annual overhauls at our
continuous casting plants, and steadily reduced the need for scheduled
facility shutdowns. Over the next four years, we will continue to
extend maintenance intervals and optimize the use of our maintenance
resources as we aim to reduce maintenance costs by around KRW 500
billion annually at each of our steelworks.
Procuring Competitiveness
In 2003, we purchased a total of 73,773,000 tons of raw materials,
including 41,290,000 tons of iron ore, 19,871,000 tons of coal,
1,444,000 tons of metallics, and 743,000 tons of stainless steel
materials such as nickel, ferrochrome, and stainless scrap. While
total materials purchased increased by 2.8% in terms of tonnage,
higher international prices in virtually all major raw materials
categories and logistics costs pushed expenditures up 19.5% to KRW
5,200 billion. Over the years, we have partnered with major international
raw materials suppliers to develop mines and build processing facilities
to secure a stable supply of materials for our operations. We have
invested in coal mines in Australia and Canada since the early 1980s,
and our joint ventures in Brazil and South Africa have been producing
iron ore pellets and ferrochrome since 1998. In October 2003, our
POSMAC iron ore mine venture with BHP Billiton in Australia officially
opened, marking our debut in this key resource development field.
As expanding global mill capacity in China and elsewhere, continues
to tighten supply, we are aggressively moving to ensure our materials
procurement needs are met through long-term contracts and larger
bulk purchases. At the same time, we continue to lower costs by
increasing purchases of inexpensive materials as well as sourcing
from regional suppliers. We have also begun using futures markets
to procure a portion of our requirements for materials such as nickel
that are currently experiencing significant price volatility. Since
1983, we have retained a fleet of bulk carrier vessels to transport
our raw materials. Our 37-vessel fleet currently delivers 75% of
our requirements, with the remaining 25% covered through short-
and long-term chartering contracts. We believe this strategy gives
us the flexibility to minimize the impact of increasing volatility
in the global shipping industry.
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