• Industries
    • Major Capital Projects
    • Construction and Infrastructure
    • Manufacturing
  • Services
    • Transformation Consultants
    • High Integrity Turnarounds™
    • Safety Consultants
    • Leadership and Organizational Performance
    • High Performance Projects™
    • The School of Coaching
  • Impact
    • What Clients Say
    • Client Results
  • Insights
    • Articles, Blogs & Poetry
    • Press Releases
    • Events
    • Transformation Talks Podcast
    • News
  • People
    • Senior Partners
    • Partners
    • Managing Consultants
    • Board of Directors
    • Founders
  • About Us
    • Our History
    • Our Vision
    • Our Perspective
  • Careers
  • Contact Us
  • Let's Talk

Over the Course of the Three Capital Projects, GS Caltex Celebrates Dramatic Results

Published by Mike Goddu at January 13, 2013
JMJ Associates Logo
GS Caltex - Celebrating IIF Success
Latest News
  • Success Stories
  • Safety

Over the Course of the Three Capital Projects, GS Caltex Celebrates Dramatic Results

The GS Caltex IIF journey has been implemented in three phases over the course of the three megaprojects. The first project saw a top-down introduction to the IIF approach, the second was integration into the overall GS Caltex culture, and the third project has seen a thriving, active IIF culture.

The first private oil company in South Korea and the country’s refining industry leader, GS Caltex provides a supply of more than 30% of the domestic petroleum market in Korea. With world-class oil refining and petrochemical production facilities, GS Caltex transforms imported crude oil into high value added petroleum and petrochemical products and exports overseas. GS Caltex has a state-of-the-art manufacturing system with a refining capacity of 775,000 barrels/day and a desulfurizing capacity of 272,000 barrels/day. In order to keep up with the market's changing demands, GS Caltex is continuously expanding its heavy oil upgrading (HOU) facilities. With the scheduled completion of the fourth HOU facility, VGO FCC, GS Caltex will have an upgrading capacity of 268,000 barrels/day, the largest in Korea.

Business Challenges



Since 2004, GS Caltex has undertaken three major megaprojects constructing Heavy Oil Upgrade facilities. VGO HCR, the first of these—and the first implementation of the IIF approach in the country—was a billion dollar project with over 6000 workers. While the goal of GS Caltex management was to complete the project as safely as possible, there were a number of initial concerns. At the time throughout the country, there was the general perception among Engineering, Procurement and Construction contractors that a focus on safety got in the way of production, and that the financial costs would outweigh the benefits. Because Korea’s construction industry was so heavily schedule driven, these concerns posed some doubts about the IIF™ Safety approach.

Along with this, there were other initial concerns on the parts of workers and contractors: that the IIF Safety approach might not be suitable for the Asian culture, that a project without incidents and injuries would not be possible on a project of that size, and that the IIF Safety approach might just be window dressing rather than a genuine commitment. There was also the mindset of some contractors on the project that the IIF Safety approach was an obligation handed down by GS Caltex rather than something worth taking ownership over.

Along with the general demands that such projects set forward, the overall construction culture throughout the country proved challenging for worker safety. Often worker facilities were in poor condition. There were few, if any, worker rest areas, and communication was usually very authoritative rather than cooperative.

Client Goals



  • To complete three megaprojects without incidents or injuries
  • To shift the overall mindset around safety from obligation to ownership
  • To have a safety record lower than industry average and within target numbers
  • To fundamentally change the culture of the construction industry in South Korea

GS Caltex and the JMJ IIF Approach



The GS Caltex IIF journey has been implemented in three phases over the course of the three megaprojects. The first project saw a top-down introduction to the IIFapproach, the second was integration into the overall GS Caltex culture, and the third project has seen a thriving, active IIF culture.

During the first phase, JMJ delivered six two-day workshops to 178 managers and site leaders initiating them into the IIF approach and engaging their commitment to no incidents and injuries. This extended into the formation of a site IIF leadership team led by GS Caltex staff. This led to IIF train-the-trainers events preparing site staff to orient others to the IIF approach, Town Hall meetings every month, and IIF orientations led by GS Caltex and delivered to all personnel.

As a result of this, GS Caltex and site workers created Recognition Awards for strong IIF performance, IIF nights, safety campaigns and magazines, and regular coaching.

While the foundation was laid during the first megaproject, the second was an opportunity to strengthen the IIF culture and bring a focus on middle management. This led to ongoing programs strengthening managements’ understanding of the IIF approach, supervisor skills training and monthly IIF coaching by JMJ consultants, along with two-day workshops to ensure site leadership was engaged with the commitment to no incidents and injuries. A mentor program was created that allowed staff to guide other workers towards a more full understanding of the safety approach, and there was a clear visual identity throughout the site that strengthened the integration of IIFsafety into the GS Caltex culture.

“JMJ helped change the mindset and perspective of workers on the project,” said Mr. Dong-Wan Woo, Construction Manager/Senior Manager, GS Caltex VGO FCC Project, GS Engineering & Construction. “There were very systematic programs. Not only did they hold workshops that helped change our mindset, but they followed up on workshops with group coaching. Because it was a constant process and there were regular trainings and coaching, it helped people be reminded of the IIF [approach] constantly.”

By the time the third megaproject began, the IIF culture had taken hold, and GS Caltex and JMJ were in a position to raise the bar on the safety culture with similar workshops and trainings, which continue today.

Client Results



Over the course of the three mega-projects, GS Caltex has seen dramatic results.

Not only were the safety records seeing drastic improvements, the projects themselves have been completed with numbers well under industry average, based on numbers by Independent Project Analysis, Inc. (IPA). The VGO HCR project was completed in 28% less time than the industry average, and its cost was 8% less. The VR HCR project also was completed below average cost and time (final numbers have not been released by IPA).

Over the course of eight years, GS Caltex management remained firm in their safety commitment, and the result has been a transformed culture with workers exhibiting care and concern for their co-workers, mutual trust and respect, and an environment of looking out for one another. There has been a noticeable shift in ownership of the IIF Safety approach as workers across GS Caltex are fully adopting the commitment to safety.

Along with these shifts, facilities have improved. There are more rest areas for workers, rest and welfare facilities have improved, and the overall communication of the culture has shifted from an authoritative culture to a more collaborative culture with open communication, joint safety checks, and safety inspections on site conducted by union and safety leaders.

Not only is this influencing GS Caltex workers, it has also had a major impact on contractors working on the project.

Client Results



Safety Results
88%

Reduction in their Total Recordable Incident Rate from 0.36 to 0.4

Safety Results
86%

Reduction in Days Away From Work Rate (DAFWR) From 0.16 to 0.02

Project Schedule
28%

VGO HCR Mega Project Completed in Less Time Than Industry Average

Project Costs
8%

Reduction in Project Costs

Contact Us to Learn More

View All Client Testimonials

Testimonials
Senior Vice President of Petrochemicals shares Joint Venture Mega Project Success
Ron Corn, Senio
Safety Testimonials
Daewoo E&C Achieves Project Success by Creating a Strong Safety Culture on a Major Infrastructure Project
Strong leadersh
American Infrastructure
Safety Testimonials
American Infrastructure
Up until 2005 w
Safety Testimonials
Qatar Shell Safety leadership Coach Describes the Special Contributions JMJ Brings to Drive Change
Qatar Shell is
COO Shares His Safety Leadership, Culture and Performance Journey at Seaway Heavy Lifting
Safety Testimonials
COO Shares his Safety Leadership, Culture and Performance Journey at Seaway Heavy Lifting
Lifting operati


JMJ helped change the mind-set and perspective of workers on the project. There were very systematic programs. Not only did they hold workshops that helped change our mind-set, but they followed up on workshops with group coaching. Because it was a constant process and there were regular training and coaching, it helped people be reminded of the IIF [approach] constantly.”

Mr. Dong-Wan Woo<br/>Construction Manager/Senior Manager, VGO FCC Project<br/>GS Engineering & Construction


Download to Read More


Generic IconClient

GS Caltex

Generic IconIndustry

Construction/Oil Refining and Petroleum Production

Generic IconJMJ Service

Safety: Delivering Incident and Injury-Free™ (IIF™) Results



Mike Goddu
The GS Caltex IIF journey has been implemented in three phases over the course of the three megaprojects. The first project saw a top-down introduction to the IIF approach, the second was integration into the overall GS Caltex culture, and the third project has seen a thriving, active IIF culture.

JMJ
  • Corporate Headquarters
    Arboretum Plaza One
    9442 N. Capital of Texas Highway, Suite 450,
    Austin, Texas 78759
  • +1 (512) 795-0795
  • Email Us

Industries

  • Rail
  • Construction
  • Manufacturing
  • Energy
  • Mining
  • Logistics
  • Aerospace
  • Water and Environmental

Services

  • Incident and Injury-Free™
  • High Performance Projects™
  • Safety Consultants
  • Leadership and Organizational Performance
  • High Integrity Turnarounds™
  • The School of Coaching

Locations

  • Americas Office – Austin
  • APAC Office – Singapore
  • EMEA Office – London
  • Middle East Office – Doha
  • Kazakhstan Office – Atyrau
  • South Korea Office – Seoul
  • Australia Office – Perth

Connect

  • linkedin
  • facebook
  • twitter
  • Youtube
  • Instagram
Privacy | Terms of Use | Trademarks | Accessibility | Cookie Policy | Feedback | Site Map |

© 2020 JMJ Associates LLP. All rights reserved. Republication or redistribution of JMJ Associates content or logo, including by framing or similar means, is prohibited without the prior written consent of JMJ Associates.

    Start Unlocking Human Performance


    Arrange a call with one of our consultants today. Please complete your details below:

    • This field is for validation purposes and should be left unchanged.
    This site uses cookies to provide you with a more personalised service. By using this site you agree to our use of cookies. Please read our cookie policy for more information on the cookies we use and how to delete or block them.Accept Read More
    Privacy & Cookies Policy

    Privacy Overview

    This website uses cookies to improve your experience while you navigate through the website. Out of these, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website. These cookies will be stored in your browser only with your consent. You also have the option to opt-out of these cookies. But opting out of some of these cookies may affect your browsing experience.
    Necessary
    Always Enabled

    Necessary cookies are absolutely essential for the website to function properly. This category only includes cookies that ensures basic functionalities and security features of the website. These cookies do not store any personal information.

    Non-necessary

    Any cookies that may not be particularly necessary for the website to function and is used specifically to collect user personal data via analytics, ads, other embedded contents are termed as non-necessary cookies. It is mandatory to procure user consent prior to running these cookies on your website.