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UNITED STATES
SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
FORM 10-Q
(Mark One) | |
ý | QUARTERLY REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 |
For the quarterly period ended: August 28, 2005 |
OR |
o | TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 |
For the transition period from to |
Commission file number 333-117081-27
SEALY MATTRESS CORPORATION
(Exact name of registrant as specified in its charter)
Delaware (State or other jurisdiction of incorporation or organization) | | 20-1178482 (I.R.S. Employer Identification No.) |
Sealy Drive One Office Parkway Trinity, North Carolina (Address of principal executive offices)* | |
27370 (Zip Code) |
(336) 861-3500 Registrant's telephone number, including area code |
Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities and Exchange Act of 1934 during the preceding 12 months and (2) has been subject to such filing requirements for the past 90 days. Yes ý No o
Indicate by check mark whether the registrant is an accelerated filer (as defined in Rule 12b-2 of the Exchange Act). Yes o No ý
As of September 30, 2005 the registrant had 1,000 shares of common stock outstanding.
PART I. FINANCIAL INFORMATION
Item 1. Financial Statements
SEALY MATTRESS CORPORATION
Condensed Consolidated Statements of Operations
(in thousands)
(unaudited)
| | Quarter Ended August 28, 2005
| | Quarter Ended August 29, 2004
| |
---|
Net sales | | $ | 390,026 | | $ | 357,263 | |
Costs and expenses: | | | | | | | |
| Cost of goods sold | | | 214,081 | | | 193,945 | |
| |
| |
| |
| | Gross profit | | | 175,945 | | | 163,318 | |
| Selling, general and administrative | | | 117,905 | | | 119,885 | |
| Recapitalization expense | | | — | | | 394 | |
| Amortization of intangibles | | | 122 | | | 297 | |
| Royalty income, net | | | (3,603 | ) | | (3,875 | ) |
| |
| |
| |
Income from operations | | | 61,521 | | | 46,617 | |
| Interest expense | | | 17,286 | | | 17,324 | |
| Other (income) expense, net | | | (70 | ) | | (102 | ) |
| |
| |
| |
Income before income tax expense | | | 44,305 | | | 29,395 | |
Income tax expense | | | 16,752 | | | 9,003 | |
| |
| |
| |
Net income | | $ | 27,553 | | $ | 20,392 | |
| |
| |
| |
See accompanying notes to condensed consolidated financial statements.
1
SEALY MATTRESS CORPORATION
Condensed Consolidated Statements of Operations
(in thousands)
(unaudited)
| | Nine Months Ended August 28, 2005
| | Nine Months Ended August 29, 2004
| |
---|
Net sales—Non-affiliates | | $ | 1,104,939 | | $ | 984,985 | |
Net sales—Affiliates | | | — | | | 7,030 | |
| |
| |
| |
| | Total net sales | | | 1,104,939 | | | 992,015 | |
Costs and expenses: | | | | | | | |
| Cost of goods sold—Non-affiliates | | | 612,831 | | | 553,448 | |
| Cost of goods sold—Affiliates | | | — | | | 4,035 | |
| |
| |
| |
| | Total cost of goods sold | | | 612,831 | | | 557,483 | |
| |
| |
| |
| | Gross profit | | | 492,108 | | | 434,532 | |
| Selling, general and administrative | | | 336,698 | | | 327,258 | |
| Recapitalization expense | | | — | | | 133,134 | |
| Amortization of intangibles | | | 409 | | | 887 | |
| Royalty income, net | | | (9,947 | ) | | (10,578 | ) |
| |
| |
| |
Income (loss) from operations | | | 164,948 | | | (16,169 | ) |
| Interest expense | | | 53,490 | | | 51,182 | |
| Other (income) expense, net | | | 6,020 | | | (844 | ) |
| |
| |
| |
Income (loss) before income tax expense | | | 105,438 | | | (66,507 | ) |
Income tax expense (benefit) | | | 48,371 | | | (16,002 | ) |
| |
| |
| |
Net income (loss) | | $ | 57,067 | | $ | (50,505 | ) |
| |
| |
| |
See accompanying notes to condensed consolidated financial statements.
2
SEALY MATTRESS CORPORATION
Condensed Consolidated Balance Sheets
(in thousands)
(unaudited)
| | August 28, 2005
| | November 28, 2004*
| |
---|
ASSETS | | | | | | | |
Current assets: | | | | | | | |
| Cash and cash equivalents | | $ | 28,011 | | $ | 22,779 | |
| Accounts receivable, net of allowances for bad debts, cash discounts and returns | | | 198,367 | | | 172,829 | |
| Inventories | | | 54,462 | | | 51,923 | |
| Assets held for sale | | | 1,405 | | | 8,983 | |
| Deferred income taxes | | | 10,678 | | | 23,898 | |
| Prepaid expenses and other current assets | | | 11,784 | | | 18,713 | |
| |
| |
| |
| | | 304,707 | | | 299,125 | |
Property, plant and equipment, at cost | | | 325,006 | | | 309,919 | |
Less: accumulated depreciation | | | (157,956 | ) | | (145,740 | ) |
| |
| |
| |
| | | 167,050 | | | 164,179 | |
Other assets: | | | | | | | |
| Goodwill | | | 384,986 | | | 387,508 | |
| Other intangibles, net | | | 4,403 | | | 4,555 | |
| Debt issuance costs, net, and other assets | | | 35,230 | | | 41,910 | |
| |
| |
| |
| | | 424,619 | | | 433,973 | |
| |
| |
| |
| | $ | 896,376 | | $ | 897,277 | |
| |
| |
| |
LIABILITIES AND STOCKHOLDERS' DEFICIT | | | | | | | |
Current liabilities: | | | | | | | |
| Current portion of long-term obligations | | $ | 10,779 | | $ | 8,542 | |
| Accounts payable | | | 104,701 | | | 96,566 | |
| Accrued interest | | | 10,658 | | | 27,366 | |
| Accrued incentives and advertising | | | 37,759 | | | 35,829 | |
| Accrued compensation | | | 38,234 | | | 37,142 | |
| Other accrued expenses | | | 42,132 | | | 49,795 | |
| |
| |
| |
| | | 244,263 | | | 255,240 | |
Due to Parent Company | | | 7,089 | | | 3,376 | |
Long-term obligations, net | | | 916,707 | | | 965,795 | |
Other noncurrent liabilities | | | 43,430 | | | 45,774 | |
Deferred income taxes | | | 14,375 | | | 10,835 | |
Commitments and contingencies | | | — | | | — | |
Stockholders' deficit: | | | | | | | |
| Common stock | | | — | | | — | |
| Additional paid-in capital | | | 458,620 | | | 458,620 | |
| Accumulated deficit | | | (791,091 | ) | | (848,158 | ) |
| Accumulated other comprehensive income | | | 2,983 | | | 5,795 | |
| |
| |
| |
| | | (329,488 | ) | | (383,743 | ) |
| |
| |
| |
| | $ | 896,376 | | $ | 897,277 | |
| |
| |
| |
- *
- Condensed from audited financial statements.
See accompanying notes to condensed consolidated financial statements.
3
SEALY MATTRESS CORPORATION
Condensed Consolidated Statements of Cash Flows
(in thousands)
(unaudited)
| | Nine Months Ended August 28, 2005
| | Nine Months Ended August 29, 2004
| |
---|
Net cash provided by (used in) operating activities | | $ | 63,801 | | $ | (19,404 | ) |
| |
| |
| |
Cash flows from investing activities: | | | | | | | |
| | Purchase of property, plant and equipment, net | | | (19,756 | ) | | (18,718 | ) |
| | Cash received from affiliate note and investment | | | — | | | 13,573 | |
| | Proceeds from the sale of property, plant and equipment | | | 9,800 | | | 1,499 | |
| |
| |
| |
| | | | Net cash used in investing activities | | | (9,956 | ) | | (3,646 | ) |
| |
| |
| |
Cash flows from financing activities: | | | | | | | |
| Cash flows associated with financing of the recapitalization: | | | | | | | |
| | | Proceeds from issuance of common stock | | | — | | | 436,050 | |
| | | Treasury stock repurchase | | | — | | | (748,141 | ) |
| | | Proceeds from the issuance of new long-term debt | | | — | | | 1,050,000 | |
| | | Repayment of existing long-term debt | | | — | | | (737,128 | ) |
| | | Debt issuance costs | | | — | | | (36,403 | ) |
| Repayments of senior secured term loan | | | (60,000 | ) | | (25,000 | ) |
| Net borrowings under revolving credit facilities | | | 4,802 | | | — | |
| Other borrowings | | | 7,069 | | | 1,707 | |
| Equity contributions from exercise of stock options | | | — | | | 63 | |
| Other | | | (57 | ) | | (500 | ) |
| |
| |
| |
| | | | Net cash used in financing activities | | | (48,186 | ) | | (59,352 | ) |
| |
| |
| |
Effect of exchange rate changes on cash | | | (427 | ) | | (36 | ) |
Change in cash and cash equivalents | | | 5,232 | | | (82,438 | ) |
Cash and cash equivalents: | | | | | | | |
| Beginning of period | | | 22,779 | | | 101,100 | |
| |
| |
| |
| End of period | | $ | 28,011 | | $ | 18,662 | |
| |
| |
| |
See accompanying notes to condensed consolidated financial statements
4
SEALY MATTRESS CORPORATION
Notes to Condensed Consolidated Financial Statements
Note 1: Basis of Presentation
The condensed consolidated interim financial statements are unaudited, and certain information and footnote disclosures related thereto normally included in financial statements prepared in accordance with accounting principles generally accepted in the United States of America have been omitted in accordance with Rule 10-01 of Regulation S-X. In the opinion of management, the accompanying unaudited consolidated financial statements were prepared following the same policies and procedures used in the preparation of the audited consolidated financial statements and reflect all adjustments (consisting of normal recurring adjustments) necessary to present fairly the financial position of Sealy Mattress Corporation and its subsidiaries (the "Company"). The results of operations for the interim periods are not necessarily indicative of the results for the entire fiscal year. These condensed consolidated financial statements should be read in conjunction with the company's Annual Report on Form 10-K for the year ended November 28, 2004.
The preparation of financial statements in conformity with generally accepted accounting principles requires management to make estimates and assumptions that affect the amount of assets and liabilities and disclosures on contingent assets and liabilities at quarter end and the reported amounts of revenue and expenses during the reporting period. Actual results may differ from these estimates.
On April 6, 2004, Sealy Corporation, owner of 100% of the Company's common stock, completed a merger with affiliates of Kohlberg Kravis Roberts & Co. L.P. ("KKR") whereby KKR acquired 92% of Sealy Corporation's capital stock for $740.5 million. Certain of Sealy Corporation's previous stockholders, including affiliates of Bain Capital, LLC and others, retained an 8% interest in Sealy Corporation's stock. The merger was accounted for as a recapitalization. Subsequent to the recapitalization, the Company received as contributed capital all of Sealy Corporation's 100% interest in Sealy Mattress Company. The Company also replaced Sealy Corporation as the parent-guarantor of the 8.25% Senior Subordinated Notes due 2014 issued by Sealy Mattress Company. Accordingly, the Company is now the reporting guarantor-parent company and as a result of being an entity under common control has reflected the operations of Sealy Corporation prior to April 6, 2004 in a manner similar to a pooling-of-interests. Additionally, all assets, liabilities, and stockholders' deficit of Sealy Corporation existing upon the completion of the recapitalization as of April 6, 2004 have been pushed down to and included with those of the Company for all periods presented. Subsequent to the recapitalization, none of the activity of Sealy Corporation has been or will be included in the consolidated financial statements of the Company and its subsidiaries.
On June 30, 2005, the Company's parent, Sealy Corporation, filed a Registration Statement on Form S-1 with the Securities and Exchange Commission in connection with a proposed initial public offering of its common stock. The proceeds from any such offering are anticipated to be used, among other things, to redeem a portion of the Company's senior subordinated notes due in 2014.
Certain reclassifications of previously reported financial information were made to conform to the 2005 presentation.
Note 2: Recapitalization Expense
In connection with the recapitalization of April 6, 2004, the Company incurred approximately $133.1 million of expense during the nine months ended August 29, 2004. Included in recapitalization expense was $70.6 million related to debt breakage costs, merger advisory fees, management retention bonuses and other costs, $45.6 million of stock compensation expense resulting from the settlement or
5
modification of existing options, $11.8 million primarily related to the write-off of previous debt issuance costs, and various other non-cash charges of approximately $5.1 million.
Note 3: Stock Option and Restricted Stock Plans
Certain employees of the Company have been granted options to purchase the common stock of the Company's parent, Sealy Corporation. Such options are accounted for by the Company and reported herein as if granted by the Company. As permitted by FAS 123, "Accounting for Stock-Based Compensation", the Company has continued to account for its stock option and stock incentive plans through August 28, 2005 in accordance with Accounting Principles Board ("APB") Opinion No. 25, "Accounting for Stock Issued to Employees", and records no charges (except to the extent required by APB Opinion No. 25) against earnings with respect to options granted. FAS No. 148, "Accounting for Stock-Based Compensation-Transition and Disclosure an Amendment of FASB Statement No. 123" does however require interim disclosure of pro forma information regarding net income and earnings per share determined as if the Company had accounted for its stock options under the fair value method.
For purposes of this pro forma disclosure, the estimated fair value of the options is amortized as an expense over the options' vesting period. The Company recognized compensation expense under APB Opinion No. 25 totaling $45.6 million for the nine months ended August 29, 2004 in connection with the modifications of outstanding options resulting from the recapitalization, such expense being included with recapitalization expense in the accompanying condensed consolidated statements of operations.
| | Three months ended
| | Nine months ended
| |
---|
| | August 28, 2005
| | August 29, 2004
| | August 28, 2005
| | August 29, 2004
| |
---|
| |
| | (In thousands)
| |
| |
---|
Net income (loss), as reported | | $ | 27,553 | | $ | 20,392 | | $ | 57,067 | | $ | (50,505 | ) |
Add: Stock-based compensation expense included in reported net income net of related tax effects | | | 403 | | | — | | | 552 | | | 27,337 | |
Deduct: Total stock-based employee compensation expense determined under fair value based method for all awards, net of tax | | | (549 | ) | | (395 | ) | | (1,327 | ) | | (28,191 | ) |
| |
| |
| |
| |
| |
Pro forma net income (loss) | | $ | 27,407 | | $ | 19,997 | | $ | 56,292 | | $ | (49,651 | ) |
| |
| |
| |
| |
| |
The Company has elected to early adopt Statement of Financial Accounting Standards No. 123 (revised 2004), "Share-Based Payment" (FAS 123R), effective August 29, 2005, the first day of the fourth quarter of fiscal 2005. The Company expects no material impact on financial position or results of operations with regard to existing option awards outstanding on the date of adoption. The Company will recognize compensation expense if and when new awards are granted in accordance with the standard.
6
Note 4: Inventories
The major components of inventories were as follows:
| | August 28, 2005
| | November 28, 2004
|
---|
| | (In thousands)
|
---|
Raw materials | | $ | 26,781 | | $ | 27,269 |
Work in process | | | 19,444 | | | 16,626 |
Finished goods | | | 8,237 | | | 8,028 |
| |
| |
|
| | $ | 54,462 | | $ | 51,923 |
| |
| |
|
Note 5: Warranty Costs
The Company's warranty policy provides a 10-year non-prorated warranty service period on all currently manufactured Sealy Posturepedic, Stearns & Foster and Bassett bedding products and some other Sealy-branded products, and a 20-year warranty on its new TrueForm™ product line introduced late in the first quarter of fiscal 2005. The Company's policy is to accrue the estimated cost of warranty coverage at the time the sale is recorded. The change in the company's accrued warranty obligations for the periods ending August 28, 2005, November 28, 2004, and August 29, 2004 was as follows:
| | Nine Months Ended August 28, 2005
| | Fiscal Year Ended November 28, 2004
| | Nine Months Ended August 29, 2004
| |
---|
| | (In thousands)
| |
---|
Accrued warranty obligations at beginning of period | | $ | 13,857 | | $ | 9,135 | | $ | 9,135 | |
Warranty claims(1) | | | (11,366 | ) | | (14,607 | ) | | (10,989 | ) |
Warranty provisions(2) | | | 11,940 | | | 19,329 | | | 13,400 | |
| |
| |
| |
| |
Accrued warranty obligations at end of period | | $ | 14,431 | | $ | 13,857 | | $ | 11,546 | |
| |
| |
| |
| |
- (1)
- Warranty claims for the nine months ended August 28, 2005 include approximately $7.8 million for claims associated with products sold prior to November 28, 2004 that are still under warranty. Warranty claims for the nine month period ended August 29, 2004 include approximately $2.7 million resulting from a change in estimate of the portion of product returns attributable to warranties and approximately $0.7 million increase in warranty claims resulting from implementation of new product return processing procedures in May 2004 which significantly reduced warranty processing time. In estimating its warranty obligations, the Company considers the impact of recoverable salvage value on warranty cost in determining its estimate of future warranty obligations. Warranty claims and provisions shown above do not include estimated salvage recoveries that reduced cost of sales by $3.5 million, $3.7 million and $2.9 million for the nine months ended August 28, 2005, the year ended November 28, 2004 and the nine months ended August 29, 2004, respectively.
- (2)
- The provision for the nine months ended August 28, 2005 includes approximately $0.5 million associated with a change in the sales agreement in the third quarter of fiscal 2005 with one of the Company's customers such that the customer is now allowed to return defective products. Previously, the customer received a discount in lieu of returning products. The provision also includes approximately $0.9 million associated with increased claims in certain international locations. In addition, the warranty provision for the nine months ended August 28, 2005 includes
7
an increase of $0.9 million related to the increase in average age and a decrease of $1.2 million related to increased recoverable salvage value included in the warranty obligation estimate. The warranty provision for the nine months ended August 29, 2004 includes approximately $2.7 million resulting from a change in estimate of the portion of product returns attributable to warranties and $1.1 million of other reserve adjustments associated with 2003. In addition, the warranty provision for the nine months ended August 29, 2004 includes $1.6 million of increased recoverable salvage value included in the warranty obligation estimate.
Note 6: Assets Held for Sale
Property, plant and equipment being held for disposal is reported at the lower of the carrying amount or fair value less costs to sell. Such assets which meet the criteria of FAS 144 to be reported as "assets held for sale" are shown as such in the accompanying balance sheets, and consist of land and buildings at the Company's closed manufacturing facilities which are being actively marketed for sale and which the Company expects to sell within one year. The $7.6 million decline in assets held for sale from November 28, 2004 to August 28, 2005 primarily results from the December 2004 sale of the Company's Randolph, Massachusetts facility (which ceased operations in May 2004), and the July 2005 sales of the Company's facilities in Memphis, Tennessee and Lake Wales, Florida (which ceased operations in fiscal 2001 and fiscal 2002, respectively). The sales resulted in gains of approximately $2.0 million and $2.2 million for the three and nine months ended August 28, 2005, respectively, which are included in income from operations as a reduction of selling, general and administrative expenses.
Note 7: Goodwill and Other Intangible Assets
The Company performs an annual assessment of its goodwill for impairment as of the beginning of the fiscal fourth quarter. The Company also assesses its goodwill and other intangible assets for impairment when events or circumstances indicate that their carrying value may not be recoverable from future cash flows.
The changes in the carrying amount of goodwill for the nine months ended August 28, 2005 are as follows (in thousands):
Balance as of November 28, 2004 | | $ | 387,508 | |
Decrease due to foreign currency translation | | | (2,522 | ) |
| |
| |
Balance as of August 28, 2005 | | $ | 384,986 | |
| |
| |
Total other intangibles of $4.4 million (net of accumulated amortization of $4.7 million) as of August 28, 2005 primarily consist of acquired licenses, which are amortized on the straight-line method over periods ranging from 5 to 15 years, and an intangible asset consisting of unamortized pension prior service costs of $1.2 million.
Note 8: Other (Income) Expense, Net
Other (income) expense, net for the nine months ended August 28, 2005 includes approximately $6.2 million of expense incurred in connection with the refinancing of the Company's senior secured credit agreement on April 14, 2005 (see Note 9—Long-Term Obligations).
Other (income) expense, net includes interest income of $0.1 million and $0.2 million for the three and nine months ended August 28, 2005 and $0.1 million and $0.8 million for the three and nine months ended August 29, 2004, respectively.
8
Note 9: Long-Term Obligations
Long-term debt as of August 28, 2005 and November 28, 2004 consisted of the following:
| | August 28, 2005
| | November 28, 2004
| |
---|
| | (in thousands)
| |
---|
Senior Revolving Credit Facility | | $ | 10,010 | | $ | 5,000 | |
Senior Secured Term Loan | | | 510,000 | | | 470,000 | |
Senior Unsecured Term Loan | | | — | | | 100,000 | |
Senior Subordinated Notes | | | 390,000 | | | 390,000 | |
Other | | | 17,476 | | | 9,337 | |
| |
| |
| |
| | | 927,486 | | | 974,337 | |
Less current portion | | | (10,779 | ) | | (8,542 | ) |
| |
| |
| |
| | $ | 916,707 | | $ | 965,795 | |
| |
| |
| |
The total borrowing capacity under the senior revolving credit facility is $125 million, of which up to $25 million may be borrowed in Canada. At August 28, 2005, amounts outstanding under the senior revolving credit facility included $10.0 million under the Canadian portion of the facility. At August 28, 2005, the Company had approximately $80.1 million total available under the revolving credit facility after taking into account letters of credit issued totaling $34.9 million.
Annually, the Company may be required to make principal prepayments equal to 50% of excess cash flow for the preceding fiscal year, as defined in its senior secured credit agreement. At August 28, 2005, the Company estimates that there will be no such required prepayment due in the first quarter of fiscal 2006 due to the $60.0 million of voluntary prepayments made during the nine months ended August 28, 2005. Subsequent to August 28, 2005, the Company has prepaid an additional $10.0 million of its senior secured term debt.
On April 14, 2005, the Company entered into the Second Amended and Restated Credit Agreement (the "Second Amended and Restated Credit Agreement"), which amended and restated the Amended and Restated Credit Agreement, dated as of August 8, 2004 (the "Existing Credit Agreement"). The Second Amended and Restated Credit Agreement amended the Existing Credit Agreement to refinance the $465 million outstanding under the existing senior secured term loans plus an additional $100 million new term loan borrowings, the proceeds of which were used to repay the $100 million outstanding under the Company's senior unsecured term loan due April 6, 2013. The Second Amended and Restated Credit Agreement also reduced the applicable interest rate margin charged on the senior secured term loan, provided certain financial leverage ratio tests are met. In addition, the Second Amended and Restated Credit Agreement provides the Company with greater flexibility to make dividend distributions to its parent, Sealy Corporation, or to repay certain subordinated debt, provided certain leverage ratio tests and other conditions are met. The terms and conditions of the Company's $125 million senior revolving credit facility were unchanged by the Second Amended and Restated Credit Agreement. In connection with the amendment and restatement, the Company incurred a charge of $6.2 million during the second quarter of fiscal 2005, including $3.3 million for the write-off of deferred finance charges primarily related to the senior unsecured term loan, $2.0 million of prepayment penalties related to the senior unsecured term loan, and $0.9 million of related fees and expenses (see Note 8—Other (income) expense, net).
9
In August 2005, the Company entered into a capital lease for the acquisition of computer hardware and software. Future minimum lease payments with the present value of the net minimum lease payments (included in other long-term debt and current portion shown above) as of August 28, 2005 are as follows:
Fiscal Year
| |
| |
---|
| 2005 | | $ | 127 | |
| 2006 | | | 510 | |
| 2007 | | | 510 | |
| 2008 | | | 382 | |
| |
| |
Total minimum lease payments | | | 1,529 | |
Less: Amount representing interest | | | (141 | ) |
| |
| |
Present value of net minimum lease payments | | $ | 1,388 | |
| |
| |
Note 10: Recently Issued Accounting Pronouncements
In November of 2004, the FASB issued SFAS 151, "Inventory Costs, an amendment of ARB No. 43 Chapter 4, "Inventory Pricing," to clarify the accounting for abnormal amounts of idle facility expense, freight, handling costs, and wasted material (spoilage) and requires that those items be recognized as current-period charges. In addition, this statement requires that allocation of fixed production overheads to the costs of conversion be based on the normal capacity of the production facilities. This statement is effective for fiscal years beginning after June 15, 2005. The Company will adopt this statement as of the beginning of fiscal 2006, and does not expect that it will have a material impact on our financial position or results of operations.
In December 2004, the FASB issued FAS 123 (Revised), "Share-Based Payment" ("FAS 123R") which replaces FAS 123 and supercedes APB Opinion No. 25, "Accounting for Stock Issued to Employees" ("APB 25"). This statement requires compensation costs relating to share-based payment transactions to be recognized in financial statements based upon the fair value of the award. FAS 123R eliminates the option to account for the cost of stock-based compensation using the intrinsic value method as allowed under APB 25. The Company will adopt the provisions of FAS 123R as of August 29, 2005, the first day of the fourth quarter of fiscal 2005. The Company expects no material impact on financial position or results of operations with regard to existing option awards outstanding on the date of adoption. The Company will recognize compensation expense if and when new awards are granted, in accordance with the standard.
Note 11: Hedging Strategies
In 2000, the Company entered into an interest rate swap agreement that effectively converted $236 million of its floating-rate debt to a fixed-rate basis through December 2006, thereby hedging against the impact of interest rate changes on future interest expense (forecasted cash flows). Use of hedging contracts allows the Company to reduce its overall exposure to interest rate changes, since gains and losses on these contracts will offset losses and gains on the transactions being hedged. The Company formally documents all hedged transactions and hedging instruments, and assesses, both at inception of the contract and on an ongoing basis, whether the hedging instruments are effective in offsetting changes in cash flows of the hedged transaction. The fair values of the interest rate agreements are estimated by obtaining quotes from brokers and are the estimated amounts that the
10
Company would receive or pay to terminate the agreements at the reporting date, taking into consideration current interest rates and the current creditworthiness of the counterparties. Effective June 3, 2002, the Company dedesignated the interest rate swap agreement for hedge accounting. As a result of the dedesignation, $12.9 million previously recorded in accumulated other comprehensive loss as of the date of dedesignation was being amortized into interest expense over the remaining life of the interest rate swap agreement. Due to the retirement of the existing debt in connection with the April 2004 recapitalization, the remaining $4.7 million previously recorded in accumulated other comprehensive loss was charged to expense during the second fiscal quarter of 2004. Prior to the recapitalization, $0.9 million was amortized into interest expense. Prior to June 3, 2002, the changes in the fair market value of the interest rate swap were recorded in accumulated other comprehensive income (loss). Subsequent to June 3, 2002, changes in the fair market value of the interest rate swap are recorded in interest expense. For the three and nine months ended August 28, 2005, ($0.3) million and ($0.6) million, and for the three and nine months ended August 29, 2004, $1.0 million and $1.4 million, respectively, was recorded as net additions to (reductions of) interest expense as a result of the cash requirements of the swap net of the non-cash interest associated with the change in its fair market value. At August 28, 2005 and November 28, 2004, the fair value carrying amount of this instrument was recorded as follows:
| | August 28, 2005
| | November 28, 2004
|
---|
| | (in thousands)
|
---|
Accrued interest | | $ | 626 | | $ | 1,162 |
Other accrued expenses | | | 1,606 | | | 3,030 |
Other noncurrent liabilities | | | 270 | | | 2,250 |
| |
| |
|
| Net liability | | $ | 2,502 | | $ | 6,442 |
| |
| |
|
During the second quarter of 2002, the Company entered into another interest rate swap agreement that has the effect of reestablishing as floating rate debt the $236 million of debt previously converted to fixed rate debt through December 2006. This interest rate swap agreement has not been designated for hedge accounting and, accordingly, any changes in the fair value are recorded in interest expense. For the three and nine months ended August 28, 2005, $0.3 million and $0.7 million, and for the three and nine months ended August 29, 2004, ($0.9) million and ($1.3) million, respectively, was recorded as net additions to (reductions of) interest expense as a result of the cash interest received on the swap net of the non-cash interest associated with the change in its fair market value. At August 28, 2005 and November 28, 2004, the fair value carrying amount of this instrument was a deminimis amount and $2.2 million, respectively, with $0.1 million and $1.8 million recorded in prepaid expenses and other current assets, and $0.1 million recorded in other noncurrent liabilities and $0.3 million recorded in noncurrent assets, respectively.
In June 2004, the Company entered into an additional swap agreement that has the effect of converting $200 million of the floating-rate debt under the Company's new senior credit facilities to a fixed-rate basis through November 2005, declining to $150 million through November 2007. The Company has formally designated this swap agreement as a cash flow hedge and expects the hedge to be highly effective in offsetting fluctuations in the designated interest payments resulting from changes in the benchmark interest rate. Accordingly, the effective portion of changes in the market value of the swap is recorded in other comprehensive income (loss). For the three and nine months ended August 28, 2005, $0.2 million and $1.3 million was recorded in interest expense. For the three and nine
11
months ended August 29, 2004, $0.7 million was recorded in interest expense. At August 28, 2005 and November 28, 2004, the fair value carrying amount of the instrument was recorded as follows:
| | August 28, 2005
| | November 28, 2004
| |
---|
| | (in thousands)
| |
---|
Accrued interest payable | | $ | 202 | | $ | 978 | |
Prepaid expense | | | (499 | ) | | — | |
Other accrued expenses | | | — | | | 1,420 | |
Long term receivable | | | (1,600 | ) | | (377 | ) |
| |
| |
| |
| Net (asset) liability | | $ | (1,897 | ) | $ | 2,021 | |
| |
| |
| |
At August 28, 2005 and November 28, 2004, accumulated other comprehensive income (loss) associated with the interest rate swaps was $1.3 million and $(0.6) million, respectively.
To protect against the reduction in value of forecasted foreign currency cash flows resulting from purchases in a foreign currency, the Company has instituted a forecasted cash flow hedging program. The Company hedges portions of its purchases denominated in foreign currencies with forward and option contracts. The Company does not designate its foreign currency hedges for accounting purposes, therefore all changes in fair value are charged to earnings. At August 28, 2005, the Company had forward contracts to sell a total of 30.5 million Canadian dollars with expiration dates ranging from September 2, 2005 through November 15, 2006. At August 28, 2005 and November 28, 2004, the fair value of the Company's net obligation under the forward contracts was a liability of $0.9 million and $3.1 million, respectively. For the three and nine months ended August 28, 2005 and August 29, 2004, the Company recognized foreign currency transaction losses of $0.8 million and gains of $2.0 million, respectively, for 2005 and losses of $0.7 million and gains of $0.6 million, respectively, for 2004.
12
Note 12: Defined Benefit Pension Expense
The components of net periodic pension cost recognized for the Company's defined benefit pension plan for the three and nine months ended August 28, 2005 and August 29, 2004 are as follows (in thousands):
| | Three months ended
| | Nine months ended
| |
---|
| | August 28, 2005
| | August 29, 2004
| | August 28, 2005
| | August 29, 2004
| |
---|
Service cost | | $ | 149 | | $ | 118 | | $ | 446 | | $ | 355 | |
Interest cost | | | 196 | | | 179 | | | 587 | | | 538 | |
Expected return on plan assets | | | (186 | ) | | (136 | ) | | (558 | ) | | (408 | ) |
Amortization of unrecognized losses | | | 36 | | | 56 | | | 109 | | | 294 | |
Amortization of unrecognized transition asset | | | (22 | ) | | (22 | ) | | (65 | ) | | (66 | ) |
Amortization of unrecognized prior service cost | | | 50 | | | 40 | | | 149 | | | 121 | |
| |
| |
| |
| |
| |
Net periodic pension cost* | | $ | 223 | | $ | 235 | | $ | 668 | | $ | 834 | |
| |
| |
| |
| |
| |
Cash contributions | | $ | 300 | | $ | 1,381 | | $ | 600 | | $ | 1,845 | |
| |
| |
| |
| |
| |
- *
- Net periodic pension costs recognized for the three and nine months ending August 29, 2004 were based upon preliminary estimates pending the final actuarial determination of such costs for fiscal 2004, which was completed in October, 2004.
The Company expects to make additional cash contributions to the plan of approximately $0.3 million during the remainder of fiscal 2005.
Note 13: Stockholders' Deficit
Activity in Stockholders' deficit is as follows (dollars in thousands):
| | Comprehensive Income
| | Common Stock
| | Additional Paid-in Capital
| | Accumulated Deficit
| | Accumulated Other Comprehensive Income (Loss)
| | Total
| |
---|
Balance at November 28, 2004 | | | | | $ | — | | $ | 458,620 | | $ | (848,158 | ) | $ | 5,795 | | $ | (383,743 | ) |
Comprehensive Income: | | | | | | | | | | | | | | | | | | | |
| Net income for the nine months ended August 28, 2005 | | $ | 57,067 | | | — | | | — | | | 57,067 | | | — | | | 57,067 | |
| Change in fair value of cash flow hedge | | | 1,886 | | | — | | | — | | | — | | | 1,886 | | | 1,886 | |
| Foreign currency translation adjustment | | | (4,698 | ) | | — | | | — | | | — | | | (4,698 | ) | | (4,698 | ) |
| |
| |
| |
| |
| |
| |
| |
Balance at August 28, 2005 | | $ | 54,255 | | $ | — | | $ | 458,620 | | $ | (791,091 | ) | $ | 2,983 | | $ | (329,488 | ) |
| |
| |
| |
| |
| |
| |
| |
Total comprehensive income (loss) for the three and nine months ended August 28, 2005 was $29.4 million and $54.3 million and for the three and nine months ended August 29, 2004 was $19.9 million and $(48.7) million, respectively.
13
Note 14: Income Taxes
As allowed under SFAS 109, "Accounting for Income Taxes", the Company has historically not provided for income taxes on the undistributed earnings of foreign subsidiaries that are considered to be permanently invested outside of the United States. However, the Company has evaluated the impact of the one-time favorable foreign dividend provisions enacted on October 22, 2004, as part of the American Jobs Creation Act of 2004, and determined that it qualifies for certain favorable foreign withholding rates and may repatriate earnings of some of its foreign subsidiaries during the 2005 fiscal year. During the second fiscal quarter of 2005, the Company adopted the Dividend Reinvestment Plan ("DRP"). Under the DRP, the Company plans to repatriate $50 million pursuant to Section 965 of the 1986 Internal Revenue Code, as amended. There are no plans to repatriate foreign earnings after the close of the 2005 fiscal year. The estimated income tax liability associated with the repatriation is $7.2 million, which has been included in income tax expense for the nine months ended August 28, 2005. During the nine months ended August 28, 2005, the Company repatriated $25.1 million, net of $1.3 million foreign withholding taxes, and plans to repatriate an additional $24.9 million during the fourth quarter of fiscal 2005.
Note 15: Noncash Investing and Financing Activities
In August of 2005, the Company entered into a capital lease for the acquisition of computer hardware and software. The amount recognized as a capital lease obligation was $1.4 million, with $1.0 million included in long-term obligations and $0.4 million included in the current portion of long-term debt (see Note 9).
Note 16: Commitments and Contingencies
The Company is subject to legal proceedings, claims, and litigation arising in the ordinary course of business. While the outcome of these matters is currently not determinable, management does not expect that the ultimate costs to resolve these matters will have a material adverse effect on the Company's consolidated financial position, results of operations or cash flows.
The Company is currently conducting an environmental cleanup at a formerly owned facility in South Brunswick, New Jersey pursuant to the New Jersey Industrial Site Recovery Act. The Company and one of its subsidiaries are parties to an Administrative Consent Order issued by the New Jersey Department of Environmental Protection. Pursuant to that order, the Company and its subsidiary agreed to conduct soil and groundwater remediation at the property. The Company does not believe that its manufacturing processes were the source of contamination. The Company sold the property in 1997. The Company and its subsidiary retained primary responsibility for the required remediation. The Company has completed essentially all soil remediation with the New Jersey Department of Environmental Protection approval, and has concluded a pilot test of the groundwater remediation system. During 2005, with the approval of the New Jersey Department of Environmental Protection, the Company removed and disposed of sediment in Oakeys Brook adjoining the site. The Company continues to monitor ground water at the site. The Company has recorded a reserve for $2.7 million ($3.4 million prior to discounting at 4.75%) associated with this remediation project, and it is reasonably possible that up to an additional $0.3 million may be incurred to complete the project.
The Company is also remediating soil and groundwater contamination at an inactive facility located in Oakville, Connecticut. Although the Company is conducting the remediation voluntarily, it obtained Connecticut Department of Environmental Protection approval of the remediation plan. The Company has completed essentially all soil remediation under the remediation plan and is currently
14
monitoring groundwater at the site. The Company has identified cadmium in the ground water at the site and intends to address that during fiscal 2006. The Company has recorded a reserve of approximately $0.4 million associated with the additional work and ongoing monitoring. The Company believes the contamination is attributable to the manufacturing operations of previous unaffiliated occupants of the facility.
The Company removed three underground storage tanks previously used for diesel, gasoline, and waste oil from its South Gate, California facility in March 1994 and remediated the soil in the area. Since August 1998, the Company has been working with the California Regional Water Quality Control Board, Los Angeles Region to monitor ground water at the site.
While the Company cannot predict the ultimate timing or costs of the South Brunswick, Oakville, and South Gate environmental matters, based on facts currently known, the Company believes that the accruals recorded are adequate and does not believe the resolution of these matters will have a material adverse effect on the financial position or future operations of the Company; however, in the event of an adverse decision, these matters could have a material adverse effect.
The state of California adopted new flame retardant regulations related to manufactured mattresses and box springs which became effective January 1, 2005. The Company believes that it is in full compliance with those regulations. The Company does not expect the impact of those regulations to be significant to the Company's results of operations or financial position.
Significant judgment is required in evaluating the Company's federal, state and foreign tax positions and in the determination of its tax provision. Despite the Company's belief that the its tax return positions are fully supportable, reserves have been established where the Company believes that certain tax positions are likely to be challenged and the Company may not fully prevail in overcoming these challenges. The Company may adjust these reserves as relevant circumstances evolve, such as guidance from the relevant tax authority, the Company's tax advisors, or resolution of issues in the courts. The Company's tax expense includes the impact of reserve positions and changes to reserves that it considers appropriate, as well as related interest. Because the Company is not currently undergoing examinations of any of its corporate income tax returns by tax authorities, the Company believes that it is unlikely that an audit could be initiated which would result in an assessment and payment of taxes related to these positions during the one year following August 28, 2005. The Company also cannot predict when or if any other future tax payments related to these tax positions may occur. Therefore, substantially all of the reserves for these positions are classified as noncurrent liabilities in the accompanying balance sheet.
In connection with planned capital expenditures totalling approximately $7.5 million in fiscal 2005 and 2006, the Company's European subsidiary has obtained financing commitments for approximately $5.8 million and has firm purchase commitments of approximately $2.7 million outstanding at August 28, 2005.
Note 17: Related Party Transactions
The Company previously contributed cash and other assets to Mattress Holdings International LLC ("MHI"), a company which was controlled by the Company's previous largest stockholder, Bain Capital, LLC ("Bain"), in exchange for a non-voting interest. MHI was formed to invest in domestic and international loans, advances and investments in joint ventures, licensees and retailers. The equity ownership of MHI was transferred from Bain to the Company in November 2002. In 1999, MHI, indirectly through a Bain controlled holding company, acquired a minority interest in Mattress Holdings
15
Corporation ("MHC"). MHC owns an interest in Mattress Discounters Corporation ("Mattress Discounters"), a domestic mattress retailer.
In October 2002, Mattress Discounters filed a voluntary joint petition with the U.S. Bankruptcy Court for the District of Maryland for reorganization under Chapter 11 of the U.S. Bankruptcy Code and was operating as a debtor in possession under the Bankruptcy Code. Effective March 14, 2003, Mattress Discounters emerged from bankruptcy. At the time Mattress Discounters filed for bankruptcy protection, the Company had recorded in its financial statements a $12.5 million participation in Mattress Discounters' banking facility and $16.0 million in trade receivables. The Company had fully-reserved the trade receivables. As part of the approved bankruptcy settlement, the Company received a non-controlling minority interest in Mattress Discounters and a $12.9 million secured note, guaranteed by MHC. Other entities affiliated with Bain also received a minority interest in Mattress Discounters. Sealy consummated the sale to MHC of the $12.9 million note and the equity interest that the Company received in the Mattress Discounters bankruptcy, as well as MHI's equity interest in MHC for $13.6 million. As a result of these transactions, the Company no longer has any direct interest in Mattress Discounters other than trade receivables in the normal course of business. In addition, as a result of the acquisition by KKR on April 6, 2004, Bain relinquished its controlling interest in the Company and Mattress Discounters ceased to be considered an affiliate of the Company subsequent to that date. Fiscal 2004 sales and cost of sales to Mattress Discounters during its period of affiliation with the Company up to April 6, 2004 are reported in the statement of operations as sales and cost of sales to affiliate. The Company believes that the terms on which mattresses were supplied to Mattress Discounters while an affiliate were not materially different than those that might reasonably be obtained in a comparable transaction on an arm's length basis from a person that is not an affiliate or related party.
During the three and nine months ended August 28, 2005, the Company incurred management fees of $0.5 million and $1.5 million to KKR, respectively. Also during the three and nine months ended August 28, 2005, the Company incurred $0.1 million and $1.3 million for consulting services provided by Capstone Consulting LLC, the chief executive officer of which is on the Company's board of directors.
Note 18: Segment Information
The Company has determined that it has two operating segments, domestic and international, that qualify for aggregation as prescribed in SFAS 131. Accordingly, the Company has one reportable industry segment, the manufacture and marketing of conventional and specialty bedding. For the three and nine months of ended August 28, 2005 and August 29, 2004, no one customer represented 10% or more of total net sales. Sales outside the United States for the three and nine months ended August 28, 2005 and August 29, 2004 were $77.8 million and $221.7 million and $71.5 million and $199.0 million, respectively. In addition, long-lived assets (principally property, plant and equipment and other investments) outside the United States were $50.6 million and $53.5 million as of August 28, 2005 and November 28, 2004, respectively.
16
| | Three months ended
| | Nine months ended
| |
---|
| | August 28, 2005
| | August 29, 2004
| | August 28, 2005
| | August 29, 2004
| |
---|
| | (in millions)
| |
---|
US domestic | | $ | 312.2 | | 80.1 | % | $ | 285.8 | | 80.0 | % | $ | 883.2 | | 79.9 | % | $ | 793.0 | | 79.9 | % |
International: | | | | | | | | | | | | | | | | | | | | | |
| Canada | | | 34.2 | | 8.8 | | | 30.9 | | 8.6 | | | 90.0 | | 8.1 | | | 80.6 | | 8.1 | |
| Europe | | | 26.7 | | 6.8 | | | 24.8 | | 6.9 | | | 78.7 | | 7.1 | | | 72.0 | | 7.3 | |
| Mexico | | | 5.6 | | 1.4 | | | 4.6 | | 1.3 | | | 17.4 | | 1.6 | | | 15.6 | | 1.6 | |
| Other international locations | | | 11.3 | | 2.9 | | | 11.2 | | 3.2 | | | 35.6 | | 3.3 | | | 30.8 | | 3.1 | |
| |
| |
| |
| |
| |
| |
| |
| |
| |
Total international | | | 77.8 | | 19.9 | | | 71.5 | | 20.0 | | | 221.7 | | 20.1 | | | 199.0 | | 20.1 | |
| |
| |
| |
| |
| |
| |
| |
| |
| |
| Total company | | $ | 390.0 | | 100.0 | % | $ | 357.3 | | 100.0 | % | $ | 1,104.9 | | 100.0 | % | $ | 992.0 | | 100.0 | % |
| |
| |
| |
| |
| |
| |
| |
| |
| |
Note 19: Guarantor/Non-Guarantor Financial Information
The Parent (as defined below) and each of the subsidiaries of Sealy Mattress Company (the "Issuer") that guarantee the Notes (as defined below) (the "Guarantor Subsidiaries") have fully and unconditionally guaranteed, on a joint and several basis, the obligation to pay principal and interest with respect to the 8.25% Senior Subordinated Notes due 2014 (the "Notes") of the Issuer. Substantially all of the Issuer's operating income and cash flow is generated by its subsidiaries. As a result, funds necessary to meet the Issuer's debt service obligations are provided in part by distributions or advances from its subsidiaries. Under certain circumstances, contractual and legal restrictions, as well as the financial condition and operating requirements of the Issuer's subsidiaries, could limit the Issuer's ability to obtain cash from its subsidiaries for the purpose of meeting its debt service obligations, including the payment of principal and interest on the Notes. Although holders of the Notes will be direct creditors of the Issuer's principal direct subsidiaries by virtue of the guarantees, the Issuer has subsidiaries ("Non-Guarantor Subsidiaries") that are not included among the Guarantor Subsidiaries, and such subsidiaries will not be obligated with respect to the Notes. As a result, the claims of creditors of the Non-Guarantor Subsidiaries will effectively have priority with respect to the assets and earnings of such companies over the claims of creditors of the Issuer, including the holders of the Notes.
The following supplemental consolidating condensed financial statements present:
- 1.
- Consolidating condensed balance sheets as of August 28, 2005 and November 28, 2004 and consolidating condensed statements of operations for the three and nine months ended August 28, 2005 and August 29, 2004 and the consolidating condensed statements of cash flows for the nine months ended August 28, 2005 and August 29, 2004.
- 2.
- Sealy Corporation, for periods prior to April 6, 2004, and Sealy Mattress Corporation, as Successor to Sealy Corporation from April 6, 2004 (see Note 1) (each, for the respective period, the "Parent" and a "guarantor"), Sealy Mattress Company (the "Issuer"), combined Guarantor Subsidiaries and combined Non-Guarantor Subsidiaries with their investments in subsidiaries accounted for using the equity method (see Note 1).
- 3.
- Elimination entries necessary to consolidate the Parent and all of its subsidiaries.
Separate financial statements of each of the Guarantor Subsidiaries are not presented because management believes that these financial statements would not be material to investors.
17
SEALY MATTRESS CORPORATION
Supplemental Consolidating Condensed Balance Sheet
August 28, 2005
(in thousands)
| | Sealy Mattress Corporation
| | Sealy Mattress Company
| | Combined Guarantor Subsidiaries
| | Combined Non-Guarantor Subsidiaries
| | Eliminations
| | Consolidated
| |
---|
ASSETS | | | | | | | | | | | | | | | | | | | |
Current assets: | | | | | | | | | | | | | | | | | | | |
| Cash and cash equivalents | | $ | — | | $ | 2 | | $ | 14,828 | | $ | 13,181 | | $ | — | | $ | 28,011 | |
| Accounts receivable—Non- affiliates, net | | | — | | | 33 | | | 136,134 | | | 62,200 | | | — | | | 198,367 | |
| Inventories | | | — | | | 3,287 | | | 34,112 | | | 17,063 | | | — | | | 54,462 | |
| Assets held for sale | | | — | | | — | | | 1,405 | | | — | | | — | | | 1,405 | |
| Prepaid expenses, deferred taxes and other current assets | | | — | | | 3,375 | | | 14,519 | | | 4,568 | | | — | | | 22,462 | |
| |
| |
| |
| |
| |
| |
| |
| | | — | | | 6,697 | | | 200,998 | | | 97,012 | | | — | | | 304,707 | |
Property, plant and equipment, at cost | | | — | | | 7,523 | | | 248,118 | | | 69,365 | | | — | | | 325,006 | |
Less: accumulated depreciation | | | — | | | (3,862 | ) | | (131,831 | ) | | (22,263 | ) | | — | | | (157,956 | ) |
| |
| |
| |
| |
| |
| |
| |
| | | — | | | 3,661 | | | 116,287 | | | 47,102 | | | — | | | 167,050 | |
Other assets: | | | | | | | | | | | | | | | | | | | |
| Goodwill | | | — | | | 24,741 | | | 304,774 | | | 55,471 | | | — | | | 384,986 | |
| Other intangibles, net | | | — | | | — | | | 4,086 | | | 317 | | | — | | | 4,403 | |
| Net investment in and advances to (from) subsidiaries and affiliates | | | (338,784 | ) | | 929,349 | | | (196,439 | ) | | (70,500 | ) | | (323,626 | ) | | — | |
| Debt issuance costs, net and other assets | | | — | | | 27,110 | | | 6,682 | | | 1,438 | | | — | | | 35,230 | |
| |
| |
| |
| |
| |
| |
| |
| | | (338,784 | ) | | 981,200 | | | 119,103 | | | (13,274 | ) | | (323,626 | ) | | 424,619 | |
| |
| |
| |
| |
| |
| |
| |
| | Total assets | | $ | (338,784 | ) | $ | 991,558 | | $ | 436,388 | | $ | 130,840 | | $ | (323,626 | ) | $ | 896,376 | |
| |
| |
| |
| |
| |
| |
| |
LIABILITIES AND STOCKHOLDERS' DEFICIT | | | | | | | | | | | | | | | | | | | |
Current liabilities: | | | | | | | | | | | | | | | | | | | |
| Current portion of long-term obligations | | $ | — | | $ | — | | $ | 445 | | $ | 10,334 | | $ | — | | $ | 10,779 | |
| Accounts payable | | | — | | | 343 | | | 70,515 | | | 33,843 | | | — | | | 104,701 | |
| Accrued interest | | | — | | | 566 | | | 10,024 | | | 68 | | | — | | | 10,658 | |
| Accrued incentives and advertising | | | — | | | — | | | 32,472 | | | 5,287 | | | — | | | 37,759 | |
| Accrued compensation | | | — | | | 295 | | | 31,058 | | | 6,881 | | | — | | | 38,234 | |
| Other accrued expenses | | | — | | | 1,860 | | | 32,689 | | | 7,583 | | | — | | | 42,132 | |
| |
| |
| |
| |
| |
| |
| |
| | | — | | | 3,064 | | | 177,203 | | | 63,996 | | | — | | | 244,263 | |
Due to Parent Company | | | — | | | — | | | 7,089 | | | — | | | — | | | 7,089 | |
Long-term obligations, net | | | — | | | 900,000 | | | 1,029 | | | 15,678 | | | — | | | 916,707 | |
Other noncurrent liabilities | | | — | | | 365 | | | 35,373 | | | 7,692 | | | — | | | 43,430 | |
Deferred income taxes | | | (9,296 | ) | | 1,379 | | | 16,240 | | | 6,052 | | | — | | | 14,375 | |
Stockholders' deficit | | | (329,488 | ) | | 86,750 | | | 199,454 | | | 37,422 | | | (323,626 | ) | | (329,488 | ) |
| |
| |
| |
| |
| |
| |
| |
| | Total liabilities and stockholders' deficit | | $ | (338,784 | ) | $ | 991,558 | | $ | 436,388 | | $ | 130,840 | | $ | (323,626 | ) | $ | 896,376 | |
| |
| |
| |
| |
| |
| |
| |
18
SEALY MATTRESS CORPORATION
Supplemental Consolidating Condensed Balance Sheet
November 28, 2004
(in thousands)
| | Sealy Mattress Corporation
| | Sealy Mattress Company
| | Combined Guarantor Subsidiaries
| | Combined Non- Guarantor Subsidiaries
| | Eliminations
| | Consolidated
| |
---|
ASSETS | | | | | | | | | | | | | | | | | | | |
Current assets: | | | | | | | | | | | | | | | | | | | |
| Cash and cash equivalents | | $ | — | | $ | 2 | | $ | 5,142 | | $ | 17,635 | | $ | — | | $ | 22,779 | |
| Accounts receivable, net | | | — | | | 61 | | | 106,511 | | | 66,257 | | | — | | | 172,829 | |
| Inventories | | | — | | | 1,047 | | | 35,014 | | | 15,862 | | | — | | | 51,923 | |
| Assets held for sale | | | — | | | — | | | 8,983 | | | — | | | — | | | 8,983 | |
| Prepaid expenses, deferred income taxes and other current assets | | | — | | | 4,616 | | | 33,933 | | | 4,062 | | | — | | | 42,611 | |
| |
| |
| |
| |
| |
| |
| |
| | | — | | | 5,726 | | | 189,583 | | | 103,816 | | | — | | | 299,125 | |
Property, plant and equipment, at cost | | | — | | | 6,962 | | | 233,339 | | | 69,618 | | | — | | | 309,919 | |
Less accumulated depreciation | | | — | | | (3,620 | ) | | (123,132 | ) | | (18,988 | ) | | — | | | (145,740 | ) |
| |
| |
| |
| |
| |
| |
| |
| | | — | | | 3,342 | | | 110,207 | | | 50,630 | | | — | | | 164,179 | |
Other assets: | | | | | | | | | | | | | | | | | | | |
| Goodwill | | | — | | | 24,741 | | | 304,773 | | | 57,994 | | | — | | | 387,508 | |
| Other intangibles, net | | | — | | | — | | | 4,303 | | | 252 | | | — | | | 4,555 | |
| Net investment in and advances to (from) subsidiaries | | | (389,163 | ) | | 941,617 | | | (210,360 | ) | | (94,885 | ) | | (247,209 | ) | | — | |
| Debt issuance costs, net, and other assets | | | — | | | 33,729 | | | 7,094 | | | 1,087 | | | — | | | 41,910 | |
| |
| |
| |
| |
| |
| |
| |
| | | (389,163 | ) | | 1,000,087 | | | 105,810 | | | (35,552 | ) | | (247,209 | ) | | 433,973 | |
| |
| |
| |
| |
| |
| |
| |
Total assets | | $ | (389,163 | ) | $ | 1,009,155 | | $ | 405,600 | | $ | 118,894 | | $ | (247,209 | ) | $ | 897,277 | |
| |
| |
| |
| |
| |
| |
| |
LIABILITIES AND STOCKHOLDERS' DEFICIT | | | | | | | | | | | | | | | | | | | |
Current liabilities: | | | | | | | | | | | | | | | | | | | |
| Current portion—long- term obligations | | $ | — | | $ | — | | $ | 22 | | $ | 8,520 | | $ | — | | $ | 8,542 | |
| Accounts payable | | | — | | | 189 | | | 56,056 | | | 40,321 | | | — | | | 96,566 | |
| Accrued customer incentives and advertising | | | — | | | 1,552 | | | 28,549 | | | 5,728 | | | — | | | 35,829 | |
| Accrued compensation | | | — | | | 270 | | | 29,622 | | | 7,250 | | | — | | | 37,142 | |
| Accrued interest | | | — | | | 2,518 | | | 24,790 | | | 58 | | | — | | | 27,366 | |
| Other accrued expenses | | | — | | | 5,428 | | | 39,857 | | | 4,510 | | | — | | | 49,795 | |
| |
| |
| |
| |
| |
| |
| |
| | | — | | | 9,957 | | | 178,896 | | | 66,387 | | | — | | | 255,240 | |
Due to (from) parent company | | | 3,876 | | | (500 | ) | | — | | | — | | | — | | | 3,376 | |
Long-term obligations | | | — | | | 965,000 | | | 21 | | | 774 | | | — | | | 965,795 | |
Other noncurrent liabilities | | | — | | | 2,254 | | | 34,847 | | | 8,673 | | | — | | | 45,774 | |
Deferred income taxes | | | (9,296 | ) | | 122 | | | 13,101 | | | 6,908 | | | — | | | 10,835 | |
Stockholders' equity (deficit) | | | (383,743 | ) | | 32,322 | | | 178,735 | | | 36,152 | | | (247,209 | ) | | (383,743 | ) |
| |
| |
| |
| |
| |
| |
| |
Total liabilities and stockholders' deficit | | $ | (389,163 | ) | $ | 1,009,155 | | $ | 405,600 | | $ | 118,894 | | $ | (247,209 | ) | $ | 897,277 | |
| |
| |
| |
| |
| |
| |
| |
19
SEALY MATTRESS CORPORATION
Supplemental Consolidated Condensed Statements of Operations
Three Months Ended August 28, 2005
(in thousands)
| | Sealy Mattress Corporation
| | Sealy Mattress Company
| | Combined Guarantor Subsidiaries
| | Combined Non-Guarantor Subsidiaries
| | Eliminations
| | Consolidated
| |
---|
Net sales | | $ | — | | $ | 17,241 | | $ | 303,325 | | $ | 75,098 | | $ | (5,638 | ) | $ | 390,026 | |
Costs and expenses: | | | | | | | | | | | | | | | | | | | |
| Cost of goods sold | | | — | | | 9,915 | | | 162,631 | | | 47,173 | | | (5,638 | ) | | 214,081 | |
| Selling, general and administrative | | | — | | | 1,713 | | | 95,630 | | | 20,562 | | | — | | | 117,905 | |
| Amortization of intangibles | | | — | | | — | | | 73 | | | 49 | | | — | | | 122 | |
| Royalty income, net | | | — | | | — | | | (4,117 | ) | | 514 | | | — | | | (3,603 | ) |
| |
| |
| |
| |
| |
| |
| |
Income from operations | | | — | | | 5,613 | | | 49,108 | | | 6,800 | | | — | | | 61,521 | |
| Interest expense | | | 103 | | | 16,781 | | | (155 | ) | | 557 | | | — | | | 17,286 | |
| Other (income) expense, net | | | — | | | — | | | (13 | ) | | (57 | ) | | — | | | (70 | ) |
| Loss (income) from equity investees | | | (27,612 | ) | | (24,793 | ) | | — | | | — | | | 52,405 | | | — | |
| Loss (income) from nonguarantor equity investees | | | — | | | — | | | (2,599 | ) | | — | | | 2,599 | | | — | |
| Capital charge and intercompany interest allocation | | | — | | | (15,763 | ) | | 15,099 | | | 664 | | | — | | | — | |
| |
| |
| |
| |
| |
| |
| |
Income before income taxes | | | 27,509 | | | 29,388 | | | 36,776 | | | 5,636 | | | (55,004 | ) | | 44,305 | |
Income tax (benefit) expense | | | (44 | ) | | 1,776 | | | 11,983 | | | 3,037 | | | — | | | 16,752 | |
| |
| |
| |
| |
| |
| |
| |
Net income | | $ | 27,553 | | $ | 27,612 | | $ | 24,793 | | $ | 2,599 | | $ | (55,004 | ) | $ | 27,553 | |
| |
| |
| |
| |
| |
| |
| |
20
SEALY MATTRESS CORPORATION
Supplemental Consolidated Condensed Statements of Operations
Three Months Ended August 29, 2004
(in thousands)
| | Sealy Mattress Corporation
| | Sealy Mattress Company
| | Combined Guarantor Subsidiaries
| | Combined Non-Guarantor Subsidiaries
| | Eliminations
| | Consolidated
| |
---|
Net sales | | $ | — | | $ | 14,156 | | $ | 279,163 | | $ | 69,360 | | $ | (5,416 | ) | $ | 357,263 | |
Costs and expenses: | | | | | | | | | | | | | | | | | | | |
| Cost of goods sold | | | — | | | 8,578 | | | 147,698 | | | 43,085 | | | (5,416 | ) | | 193,945 | |
| Selling, general and administrative | | | — | | | 3,876 | | | 97,379 | | | 18,630 | | | — | | | 119,885 | |
| Recapitalization expense | | | — | | | — | | | — | | | 394 | | | — | | | 394 | |
| Amortization of intangibles | | | — | | | — | | | 73 | | | 224 | | | — | | | 297 | |
| Royalty income, net | | | — | | | — | | | (4,128 | ) | | 253 | | | — | | | (3,875 | ) |
| |
| |
| |
| |
| |
| |
| |
Income from operations | | | — | | | 1,702 | | | 38,141 | | | 6,774 | | | — | | | 46,617 | |
| Interest expense | | | 60 | | | 17,431 | | | (408 | ) | | 241 | | | — | | | 17,324 | |
| Other (income) expense, net | | | (4 | ) | | — | | | (1 | ) | | (97 | ) | | — | | | (102 | ) |
| Loss (income) from equity investees | | | (21,231 | ) | | (21,035 | ) | | — | | | — | | | 42,266 | | | — | |
| Loss (income) from nonguarantor equity investees | | | — | | | (277 | ) | | (4,314 | ) | | — | | | 4,591 | | | — | |
| Capital charge and intercompany interest allocation | | | (56 | ) | | (16,595 | ) | | 16,006 | | | 645 | | | — | | | — | |
| |
| |
| |
| |
| |
| |
| |
Income before income taxes | | | 21,231 | | | 22,178 | | | 26,858 | | | 5,985 | | | (46,857 | ) | | 29,395 | |
Income tax expense | | | 839 | | | 947 | | | 5,823 | | | 1,394 | | | — | | | 9,003 | |
| |
| |
| |
| |
| |
| |
| |
Net income | | $ | 20,392 | | $ | 21,231 | | $ | 21,035 | | $ | 4,591 | | $ | (46,857 | ) | $ | 20,392 | |
| |
| |
| |
| |
| |
| |
| |
21
SEALY MATTRESS CORPORATION
Supplemental Consolidating Condensed Statements of Operations
Nine Months Ended August 28, 2005
(in thousands)
| | Sealy Mattress Corporation
| | Sealy Mattress Company
| | Combined Guarantor Subsidiaries
| | Combined Non-Guarantor Subsidiaries
| | Eliminations
| | Consolidated
| |
---|
Net sales | | $ | — | | $ | 47,585 | | $ | 859,942 | | $ | 213,731 | | $ | (16,319 | ) | $ | 1,104,939 | |
Costs and expenses: | | | | | | | | | | | | | | | | | | | |
| Cost of goods sold | | | — | | | 28,184 | | | 465,437 | | | 135,529 | | | (16,319 | ) | | 612,831 | |
| Selling, general and administrative | | | — | | | 4,750 | | | 271,144 | | | 60,804 | | | — | | | 336,698 | |
| Amortization of intangibles | | | — | | | — | | | 217 | | | 192 | | | — | | | 409 | |
| Royalty income, net | | | — | | | — | | | (11,484 | ) | | 1,537 | | | — | | | (9,947 | ) |
| |
| |
| |
| |
| |
| |
| |
Income (loss) from operations | | | — | | | 14,651 | | | 134,628 | | | 15,669 | | | — | | | 164,948 | |
| Interest expense | | | 279 | | | 52,258 | | | (246 | ) | | 1,199 | | | — | | | 53,490 | |
| Other (income) expense | | | — | | | 6,248 | | | (13 | ) | | (215 | ) | | — | | | 6,020 | |
| Loss (income) from equity investees | | | (57,241 | ) | | (53,884 | ) | | — | | | — | | | 111,125 | | | — | |
| Loss (income) from nonguarantor equity investees | | | — | | | — | | | (5,964 | ) | | — | | | 5,964 | | | — | |
| Capital charge and intercompany interest allocation | | | — | | | (49,272 | ) | | 47,223 | | | 2,049 | | | — | | | — | |
| |
| |
| |
| |
| |
| |
| |
Income before income taxes | | | 56,962 | | | 59,301 | | | 93,628 | | | 12,636 | | | (117,089 | ) | | 105,438 | |
Income tax (benefit) expense | | | (105 | ) | | 2,060 | | | 39,744 | | | 6,672 | | | — | | | 48,371 | |
| |
| |
| |
| |
| |
| |
| |
Net income | | $ | 57,067 | | $ | 57,241 | | $ | 53,884 | | $ | 5,964 | | $ | (117,089 | ) | $ | 57,067 | |
| |
| |
| |
| |
| |
| |
| |
22
SEALY MATTRESS CORPORATION
Supplemental Consolidating Condensed Statements of Operations
Nine Months Ended August 29, 2004
(in thousands)
| | Sealy Mattress Corporation
| | Sealy Mattress Company
| | Combined Guarantor Subsidiaries
| | Combined Non-Guarantor Subsidiaries
| | Eliminations
| | Consolidated
| |
---|
Net sales—Non-affiliates | | $ | — | | $ | 37,433 | | $ | 768,705 | | $ | 193,122 | | $ | (14,275 | ) | $ | 984,985 | |
Net sales—Affiliates | | | — | | | — | | | 7,030 | | | — | | | — | | | 7,030 | |
| |
| |
| |
| |
| |
| |
| |
| | Total net sales | | | — | | | 37,433 | | | 775,735 | | | 193,122 | | | (14,275 | ) | | 992,015 | |
Costs and expenses: | | | | | | | | | | | | | | | | | | | |
| Cost of goods sold—Non- affiliates | | | — | | | 23,573 | | | 423,502 | | | 120,648 | | | (14,275 | ) | | 553,448 | |
| Cost of goods sold—Affiliates | | | — | | | — | | | 4,035 | | | — | | | — | | | 4,035 | |
| |
| |
| |
| |
| |
| |
| |
| | Total cost of goods sold | | | — | | | 23,573 | | | 427,537 | | | 120,648 | | | (14,275 | ) | | 557,483 | |
| Selling, general and administrative | | | 26 | | | 10,489 | | | 260,553 | | | 56,190 | | | — | | | 327,258 | |
| Recapitalization Expense | | | 41,753 | | | 36,871 | | | 50,224 | | | 4,286 | | | — | | | 133,134 | |
| Amortization of intangibles | | | — | | | — | | | 217 | | | 670 | | | — | | | 887 | |
| Royalty income, net | | | — | | | — | | | (11,378 | ) | | 800 | | | — | | | (10,578 | ) |
| |
| |
| |
| |
| |
| |
| |
Income (loss) from operations | | | (41,779 | ) | | (33,500 | ) | | 48,582 | | | 10,528 | | | — | | | (16,169 | ) |
| Interest expense | | | 1,951 | | | 48,860 | | | (404 | ) | | 775 | | | — | | | 51,182 | |
| Other (income) expense | | | — | | | — | | | (327 | ) | | (517 | ) | | — | | | (844 | ) |
| Loss (income) from equity investees | | | 18,796 | | | (4,977 | ) | | — | | | — | | | (13,819 | ) | | — | |
| Loss (income) from nonguarantor equity investees | | | — | | | (3,521 | ) | | (2,786 | ) | | — | | | 6,307 | | | — | |
| Capital charge and intercompany interest allocation | | | (1,973 | ) | | (46,416 | ) | | 46,425 | | | 1,964 | | | — | | | — | |
| |
| |
| |
| |
| |
| |
| |
Income (loss) before income taxes | | | (60,553 | ) | | (27,446 | ) | | 5,674 | | | 8,306 | | | 7,512 | | | (66,507 | ) |
Income tax (benefit) expense | | | (10,048 | ) | | (8,650 | ) | | 697 | | | 1,999 | | | — | | | (16,002 | ) |
| |
| |
| |
| |
| |
| |
| |
Net income (loss) | | $ | (50,505 | ) | $ | (18,796 | ) | $ | 4,977 | | $ | 6,307 | | $ | 7,512 | | $ | (50,505 | ) |
| |
| |
| |
| |
| |
| |
| |
23
SEALY MATTRESS CORPORATION
Supplemental Consolidating Condensed Statements of Cash Flows
Nine Months Ended August 28, 2005
(in thousands)
| | Sealy Mattress Corporation
| | Sealy Mattress Company
| | Combined Guarantor Subsidiaries
| | Combined Non-Guarantor Subsidiaries
| | Eliminations
| | Consolidated
| |
---|
Net cash provided by operating activities | | $ | — | | $ | 3,860 | | $ | 55,977 | | $ | 3,964 | | $ | — | | $ | 63,801 | |
| |
| |
| |
| |
| |
| |
| |
Cash flows from investing activities: | | | | | | | | | | | | | | | | | | | |
| Purchase of property, plant and equipment, net | | | — | | | (609 | ) | | (18,170 | ) | | (977 | ) | | — | | | (19,756 | ) |
| Proceeds from the sale of property, plant and equipment | | | — | | | — | | | 9,800 | | | — | | | — | | | 9,800 | |
| Net activity in investment in and advances to (from) subsidiaries | | | — | | | 61,954 | | | (64,518 | ) | | 2,564 | | | — | | | — | |
| |
| |
| |
| |
| |
| |
| |
Net cash provided by (used in) investing activities | | | — | | | 61,345 | | | (72,888 | ) | | 1,587 | | | — | | | (9,956 | ) |
Cash flows from financing activities: | | | | | | | | | | | | | | | | | | | |
| Repayments of senior secured term loan | | | — | | | (60,000 | ) | | — | | | — | | | — | | | (60,000 | ) |
| Net borrowings under revolving credit facilities | | | — | | | (5,000 | ) | | — | | | 9,802 | | | — | | | 4,802 | |
| Other borrowings | | | — | | | — | | | — | | | 7,069 | | | — | | | 7,069 | |
| Intercompany dividend associated with international repatriation | | | — | | | — | | | 26,449 | | | (26,449 | ) | | — | | | — | |
| Other | | | — | | | (205 | ) | | 148 | | | — | | | — | | | (57 | ) |
| |
| |
| |
| |
| |
| |
| |
Net cash provided by (used in) financing activities | | | — | | | (65,205 | ) | | 26,597 | | | (9,578 | ) | | — | | | (48,186 | ) |
| |
| |
| |
| |
| |
| |
| |
Effect of exchange rate on cash | | | — | | | — | | | — | | | (427 | ) | | — | | | (427 | ) |
Change in cash and cash equivalents | | | — | | | — | | | 9,686 | | | (4,454 | ) | | — | | | 5,232 | |
Cash and cash equivalents: | | | | | | | | | | | | | | | | | | | |
| Beginning of period | | | — | | | 2 | | | 5,142 | | | 17,635 | | | — | | | 22,779 | |
| |
| |
| |
| |
| |
| |
| |
| End of period | | $ | — | | $ | 2 | | $ | 14,828 | | $ | 13,181 | | $ | — | | $ | 28,011 | |
| |
| |
| |
| |
| |
| |
| |
24
SEALY MATTRESS CORPORATION
Supplemental Consolidating Condensed Statements of Cash Flows
Nine Months Ended August 29, 2004
(in thousands)
| | Sealy Mattress Corporation
| | Sealy Mattress Company
| | Combined Guarantor Subsidiaries
| | Combined Non-Guarantor Subsidiaries
| | Eliminations
| | Consolidated
| |
---|
Net cash provided by (used in) operating activities | | $ | — | | $ | (21,713 | ) | $ | (6,929 | ) | $ | 9,238 | | $ | — | | $ | (19,404 | ) |
| |
| |
| |
| |
| |
| |
| |
Cash flows from investing activities: | | | | | | | | | | | | | | | | | | | |
| Purchase of property, plant and equipment, net | | | — | | | (362 | ) | | (15,808 | ) | | (2,548 | ) | | — | | | (18,718 | ) |
| Cash received from affiliate note and investment | | | — | | | — | | | — | | | 13,573 | | | — | | | 13,573 | |
| Proceeds from the sale of property, plant and equipment | | | — | | | — | | | 1,499 | | | — | | | — | | | 1,499 | |
| Net activity in investment in and advances to (from) subsidiaries | | | 362,017 | | | (278,912 | ) | | (62,194 | ) | | (20,911 | ) | | — | | | — | |
| |
| |
| |
| |
| |
| |
| |
Net cash provided by (used in) investing activities | | | 362,017 | | | (279,274 | ) | | (76,503 | ) | | (9,886 | ) | | — | | | (3,646 | ) |
Cash flows from financing activities: | | | | | | | | | | | | | | | | | | | |
| Cash flows associated with financing of the recapitalization (Note 2): | | | | | | | | | | | | | | | | | | | |
| | Proceeds from issuance of common stock | | | 436,050 | | | — | | | — | | | — | | | — | | | 436,050 | |
| | Treasury stock repurchase (including direct expenses of $7,608) | | | (748,141 | ) | | — | | | — | | | — | | | — | | | (748,141 | ) |
| | Proceeds from the issuance of new long-term debt | | | — | | | 1,050,000 | | | — | | | — | | | — | | | 1,050,000 | |
| | Repayment of existing long-term debt | | | (49,989 | ) | | (687,139 | ) | | — | | | — | | | — | | | (737,128 | ) |
| | Debt issuance costs | | | — | | | (36,403 | ) | | — | | | — | | | — | | | (36,403 | ) |
| Repayments of senior secured term loan | | | | | | (25,000 | ) | | | | | | | | | | | (25,000 | ) |
| Borrowings (repayments) of other long-term obligations, net | | | — | | | — | | | — | | | 1,707 | | | — | | | 1,707 | |
| Equity contributions from exercise of stock options | | | 63 | | | — | | | — | | | — | | | — | | | 63 | |
| Other | | | — | | | (500 | ) | | — | | | — | | | — | | | (500 | ) |
| |
| |
| |
| |
| |
| |
| |
Net cash provided by (used in) financing activities | | | (362,017 | ) | | 300,958 | | | — | | | 1,707 | | | — | | | (59,352 | ) |
| |
| |
| |
| |
| |
| |
| |
Effect of exchange rate changes on cash | | | — | | | — | | | — | | | (36 | ) | | — | | | (36 | ) |
Change in cash and cash equivalents | | | — | | | (29 | ) | | (83,432 | ) | | 1,023 | | | — | | | (82,438 | ) |
Cash and cash equivalents: | | | | | | | | | | | | | | | | | | | |
| Beginning of period | | | — | | | 31 | | | 90,985 | | | 10,084 | | | — | | | 101,100 | |
| |
| |
| |
| |
| |
| |
| |
| End of period | | $ | — | | $ | 2 | | $ | 7,553 | | $ | 11,107 | | $ | — | | $ | 18,662 | |
| |
| |
| |
| |
| |
| |
| |
25
SEALY MATTRESS CORPORATION
Item 2. Management's Discussion and Analysis of Financial Condition and Results of Operations
BUSINESS OVERVIEW
Sealy Mattress Corporation, through our subsidiaries, is the largest bedding manufacturer in the world, with a wholesale domestic market share of 20.7% in 2004. We estimate that our market share has increased slightly through August 28, 2005. We manufacture and market a complete line of bedding (innerspring and non-innerspring) products including mattresses and box springs, holding leading positions in key market segments such as luxury bedding products and among leading retailers. According toHome Furnishing News,the Sealy brand ranked 15th among the top 150 home products brands. Our conventional bedding products include the SEALY®, SEALY POSTUREPEDIC®, STEARNS & FOSTER® and BASSETT® brands and account for approximately 88.4% of the our total net sales for the year ended November 28, 2004. In addition to our innerspring bedding, we also produce a variety of visco-elastic (memory foam) and latex foam bedding products. Though sales of such products were not significant in the first nine months of 2005, we expect to experience growth in these product lines as we seek to strengthen our competitive position in the specialty bedding (non-innerspring mattress) market. We distinguish ourselves from our major competitors by maintaining our own component parts manufacturing capability and producing substantially all of our mattress innerspring requirements and approximately 46% of our boxspring component parts requirements. We believe that our industry is resilient to economic downturns due in part to the large portion of purchases, approximately 70%, which are for mattress replacements. The growth of the bedding industry has been supported by economic and demographic factors such as increasing disposable income among the "baby boomer" segment of the population, an increase in the number of bedrooms per home and second home purchases, and growing awareness of the health benefits of quality sleep.
On April 6, 2004 our parent company, Sealy Corporation, completed a merger with affiliates of Kohlberg Kravis Roberts & Co. L.P. ("KKR") whereby KKR acquired approximately 92% of Sealy Corporation's capital stock. In connection with the merger, we recapitalized substantially all of our outstanding debt. A full description of the effects of the merger and recapitalization is included in our 2004 Annual Report on Form 10-K, filed with the Securities and Exchange Commission on February 28, 2005. Although we incurred substantially increased levels of debt in the recapitalization, our cost of capital was reduced due to lower interest rates on the new debt compared with our earlier financing, and our total interest costs have remained comparable with those prior to the recapitalization. On April 14, 2005, we further reduced our cost of capital by amending and restating our senior secured credit agreement. The amendment provided an additional $100 million of senior secured term loans which were used to repay our senior unsecured term loans, reducing our interest costs going forward. Due to our strong operating cash flow since the recapitalization, we have been able to repay $150 million of our senior secured term debt significantly ahead of schedule. Our strategy for the remainder of 2005 and into 2006 is to continue to deleverage our business through additional prepayments of our long-term debt as permitted by our senior credit agreements and our operating cash flow.
On June 30, 2005, our parent company, Sealy Corporation, filed a Registration Statement on Form S-1 with the Securities and Exchange Commission in connection with a proposed initial public offering of its common stock. The proceeds from any such offering are anticipated to be used, among other things, to redeem a portion of our senior subordinated notes due in 2014.
In 2004, we successfully completed the rollout of our new single-sided, "no-flip" Sealy Posturepedic UniCased® and Stearns & Foster TripLCased® product lines in the United States, Canada, and Mexico, representing the broadest product redesign in our history. The manufacture and sale of these products for our Sealy Posturepedic lines began in mid-2003, followed by the introduction of the new Stearns & Foster lines in the first fiscal quarter of 2004. Our initial profitability from the sales of these new
26
products was limited as we worked to gain manufacturing efficiency with the new designs and supported our customers' transition to the new products with price rollbacks. In 2004, with these issues substantially behind us, we began to realize the anticipated contribution of these products to our sales growth and profitability, which has continued into 2005. Our profitability has been further enhanced by rapid growth among our high-end price point ($1,000 and up) luxury bedding lines. Our shares of the Luxury and Ultra-Luxury product segments are greater than our overall market share, and our Stearns & Foster and Luxury Posturepedic lines directly target these segments.
Late in the first quarter of 2005, we introduced our new TrueForm™ visco-elastic bedding product line to take advantage of the rapid growth of the specialty bedding category. This market, which includes latex foam, visco-elastic and air-adjustable mattress products, has experienced substantial growth both domestically and internationally. We believe that by successfully leveraging our strong brand advantage and our marketing and distribution capabilities, we have the potential to make significant gains in the specialty bedding category.
Our industry continues to be challenged by the high cost of steel and petroleum products, which affect the cost of our steel innerspring and our polyurethane foam and polyethylene component parts. Thus far, we have been able to successfully address these cost pressures through a price increase announced in May of 2004 and cost reduction efforts. During 2005, the cost of steel has continued to remain elevated above their recent historical averages, and the cost of petroleum-based foam products has increased significantly. We expect these costs to remain elevated throughout the remainder of 2005 and into 2006. See "Foam Material Supply Disruption" below for a discussion of the effects of the recent Gulf Coast hurricanes on our business.
Historically, the bedding industry has had limited exposure to competition from imports due to high shipping costs, short lead times, the large number of finished goods SKUs and the importance of brands. Although Asian bedding manufacturers have begun to explore the feasibility of exporting their products into the United States, we do not expect that competition from Asian bedding imports will have a significant impact on our business. We believe that by focusing on further improvements in the efficiency of our supply chain, controlling costs, and continuing to invest in product innovation and our brands, we can ensure that our domestically produced products will remain competitive with Asian bedding imports. Furthermore, we believe that the relatively low labor content of our domestically produced mattresses lessens any competitive advantage provided by lower Asian labor costs.
In our international markets we have continued to see significant sales growth over the last several years, with our foreign subsidiaries contributing 19.9% of our total company revenues for the nine months ended August 28, 2005. However, our Brazilian subsidiary, contributing approximately $10.6 million to our revenues for the nine months ended August 28, 2005, has continued to perform below our expectations and has not yet achieved profitability. While we do not believe that we have, as yet, suffered any impairment with respect to our investment in long-lived assets in Brazil, we will continue to monitor that operation closely as we evaluate our strategic alternatives in that market.
On October 11, 2005, Levitz Home Furnishings, Inc. announced that it had filed for protection under Chapter 11 of the United States Bankruptcy Code. We are evaluating our exposure with respect to any possible losses which may result from this bankruptcy, and will record any loss provisions in the fourth quarter of fiscal 2005.
The recent Gulf Coast hurricanes in late August and September of 2005 caused extensive damage to petrochemical processing facilities that supply an essential raw material called TDI, used to manufacture polyurethane foam, a material used in substantially all of our bedding products. As a result, there is a temporary foam shortage that will affect North American manufacturers in the mattress, furniture, and automobile seating industries. Our principal foam supplier has given notice that
27
most types of foam they supply will be on temporary allocation. At this time the duration and extent of the material shortages is unclear, but we anticipate some impact on production schedules across all of Sealy's North American mattress plants for at least a portion of the fourth quarter of fiscal 2005. By re-prioritizing our production and delivery schedules and utilizing our international operations to locate alternative sources of foam products, we believe we will be able to minimize the impact of this disruption on our customers and our business. At this time, however, we are unable to quantify any potential adverse impact this disruption may have on our results of operations for the fourth quarter of fiscal 2005 or beyond.
RESULTS OF OPERATIONS
The following table sets forth our summarized results of operations for three months ended August 28, 2005 and August 29, 2004 expressed in millions of dollars as well as a percentage of each year's net sales:
| | For the three months ended
| |
---|
| | August 28, 2005
| | August 29, 2004
| |
---|
| | millions
| | percentage of net sales
| | millions
| | percentage of net sales
| |
---|
Total net sales | | $ | 390.0 | | 100.0 | % | $ | 357.3 | | 100.0 | % |
Total cost of goods sold | | | 214.1 | | 54.9 | | | 193.9 | | 54.3 | |
| |
| |
| |
| |
| |
Gross Profit | | | 175.9 | | 45.1 | | | 163.4 | | 45.7 | |
Selling, general and administrative | | | 117.9 | | 30.2 | | | 119.9 | | 33.6 | |
Recapitalization expense | | | | | | | | 0.4 | | 0.2 | |
Amortization of intangibles | | | 0.1 | | 0.0 | | | 0.3 | | 0.1 | |
Royalty income, net of royalty expense | | | (3.6 | ) | (0.9 | ) | | (3.8 | ) | (1.1 | ) |
| |
| |
| |
| |
| |
| Income from operations | | | 61.5 | | 15.8 | | | 46.6 | | (13.0 | ) |
Interest expense | | | 17.3 | | 4.4 | | | 17.3 | | 4.8 | |
Other (income) expense, net | | | (0.1 | ) | (0.0 | ) | | (0.1 | ) | (0.0 | ) |
| |
| |
| |
| |
| |
| Income before income taxes | | | 44.3 | | 11.4 | | | 29.4 | | 8.2 | |
Income taxes | | | 16.8 | | 4.3 | | | 9.0 | | 2.5 | |
| |
| |
| |
| |
| |
Net income | | $ | 27.5 | | 7.1 | % | $ | 20.4 | | 5.7 | % |
| |
| |
| |
| |
| |
Effective tax rate | | | 37.8 | % | | | | 30.6 | % | | |
The following table indicates the percentage distribution of our net sales in U.S. dollars throughout our international operations:
| | Three Months Ended:
| |
---|
Geographic distribution of sales:
| | August 28, 2005
| | August 29, 2004
| |
---|
US Domestic | | 80.1 | % | 80.0 | % |
International: | | | | | |
| Canada | | 8.8 | | 8.6 | |
| Europe | | 6.8 | | 6.9 | |
| Mexico | | 1.4 | | 1.3 | |
| Other | | 2.9 | | 3.2 | |
| |
| |
| |
| | Total | | 100.0 | % | 100.0 | % |
| |
| |
| |
28
The following table shows our net sales and margin profitability for the major geographic regions of our operations, including local currency results for the significant international operations:
| | For the Three Months Ended:
| |
---|
| | August 28, 2005
| | August 29, 2004
| |
---|
| | millions
| | percentage of net sales
| | millions
| | percentage of net sales
| |
---|
Total Domestic (US Dollars): | | | | | | | | | | | |
| Total net sales | | $ | 312.2 | | 100.0 | % | $ | 285.8 | | 100.0 | % |
| Total cost of goods sold | | | 165.5 | | 53.0 | | | 149.5 | | 52.3 | |
| |
| |
| |
| |
| |
| | Gross profit | | | 146.7 | | 47.0 | | | 136.3 | | 47.7 | |
Total International (US Dollars): | | | | | | | | | | | |
| Total net sales | | | 77.8 | | 100.0 | | | 71.5 | | 100.0 | |
| Total cost of goods sold | | | 48.6 | | 62.5 | | | 44.4 | | 62.1 | |
| |
| |
| |
| |
| |
| | Gross profit | | | 29.2 | | 37.5 | | | 27.1 | | 37.9 | |
Canada: | | | | | | | | | | | |
| US Dollars: | | | | | | | | | | | |
| | Total net sales | | | 34.2 | | 100.0 | | | 30.9 | | 100.0 | |
| | Total cost of goods sold | | | 19.7 | | 57.6 | | | 18.1 | | 58.6 | |
| |
| |
| |
| |
| |
| | | Gross profit | | | 14.5 | | 42.4 | | | 12.8 | | 41.4 | |
| Canadian Dollars: | | | | | | | | | | | |
| | Total net sales | | | 41.9 | | 100.0 | | | 41.2 | | 100.0 | |
| | Total cost of goods sold | | | 24.1 | | 57.5 | | | 24.1 | | 58.5 | |
| |
| |
| |
| |
| |
| | | Gross profit | | | 17.8 | | 42.5 | | | 17.1 | | 41.5 | |
Europe: | | | | | | | | | | | |
| US Dollars: | | | | | | | | | | | |
| | Total net sales | | | 26.7 | | 100.0 | | | 24.8 | | 100.0 | |
| | Total cost of goods sold | | | 18.5 | | 69.3 | | | 16.1 | | 64.9 | |
| |
| |
| |
| |
| |
| | | Gross profit | | | 8.2 | | 30.7 | | | 8.7 | | 35.1 | |
| Euros: | | | | | | | | | | | |
| | Total net sales | | | 21.7 | | 100.0 | | | 20.5 | | 100.0 | |
| | Total cost of goods sold | | | 15.2 | | 70.0 | | | 13.2 | | 64.4 | |
| |
| |
| |
| |
| |
| | | Gross profit | | | 6.5 | | 30.0 | | | 7.3 | | 35.6 | |
Other International (US Dollars): | | | | | | | | | | | |
| Total net sales | | | 16.9 | | 100.0 | | | 15.8 | | 100.0 | |
| Total cost of goods sold | | | 10.4 | | 61.5 | | | 10.2 | | 64.6 | |
| |
| |
| |
| |
| |
| | Gross profit | | $ | 6.5 | | 38.5 | % | $ | 5.6 | | 35.4 | % |
Quarter Ended August 28, 2005 compared with Quarter Ended August 29, 2004
Net Sales. Net sales for the quarter ended August 28, 2005, were $390.0 million an increase of $32.7 million, or 9.2% from the quarter ended August 29, 2004. Total domestic sales were $312.2 million for the third quarter of 2005 compared to $285.8 million for the third quarter of 2004. The domestic sales increase of $26.4 million was attributable to a 4.3% increase in volume and a 4.8% increase in average unit selling price, due primarily to an improved sales mix from our new UniCased® Posturepedic and TripLCased® Stearns & Foster lines as well as our new visco-elastic and latex foam
29
specialty bedding products, and to price increases announced in May 2004 and transitioned into effect through the third quarter of fiscal 2004 to offset the effects of rising steel costs. Total international sales were $77.8 million for the third quarter of 2005 compared to $71.5 million for the third quarter of 2004, an increase of $6.3 million, or 8.8%. This increase was significantly influenced by favorable exchange rate fluctuations, most notably in our European and Canadian markets, where local currency sales gains of 5.9% and 1.7%, respectively, translated into gains of 7.7% and 10.7%, respectively, in US Dollars. Local currency changes in our Canadian market were driven by a 10.1% increase in average unit selling price resulting from price increases implemented in response to increased material costs, the successful introduction of our UniCased® product line and improved sales mix, offset by a 7.6% decline in volume, primarily among our lower price-point products resulting from our increased emphasis on sales of higher margin products. Sales gains in the European market were primarily attributable to a 19.2% increase in volume, partially offset by a 11.2% decline in average unit selling price. These changes are primarily the result of a shift in the mix of sales to include a higher volume of latex mattress cores sold to other European manufacturers relative to our sales of finished mattress products in Europe.
Cost of Goods Sold. Cost of goods sold for the quarter, as a percentage of net sales, increased 0.6 percentage points to 54.9%. Cost of goods sold for the domestic business, as a percentage of net sales, increased 0.7 percentage points to 53.0%. This increase is due primarily to higher material costs, partially offset by lower variable conversion costs. On a per unit basis, material costs increased 15.2% relative to the third quarter of 2004 due primarily to increased steel and foam product costs as well as changes in the sales mix toward higher price-point products. Variable conversion costs, however, decreased 8.9%, primarily due to increased manufacturing efficiency and lower product return costs. Product return costs associated with warranties decreased approximately $2.1 million. This decrease is primarily due to approximately $2.7 million included in the provision for the quarter ended August 29, 2004 resulting from a change in estimate of the portion of product returns attributable to warranties and $1.1 million of other reserve adjustments in the quarter ended August 29, 2004 associated with 2003. These items were partially offset by increased recoverable salvage value included in the August 29, 2004 warranty obligation calculation of $1.6 million, and $0.5 million associated with a change in the third quarter of fiscal 2005 to the sales agreement with one of the Company's customers such that the customer is now allowed to return defective products. Previously, the customer received a discount in lieu of returning products. During 2004, we enhanced our data collection process with respect to warranty returns. This enhancement allows us to determine the age of the bed based on the manufacture date and allows us to specifically identify and track reasons for the return. This information has enabled us to improve the estimation process with respect to the estimated future warranty obligation and provides better management information with which we can isolate and remedy any causes for product defects. Cost of goods sold for the international business, as a percentage of net sales, increased 0.4 percentage points to 62.5%, due to higher material and product return costs.
Selling, General, and Administrative. Selling, general, and administrative expenses decreased $2.0 million to $117.9 million for the quarter ended August 28, 2005 compared to $119.9 million for the quarter ended August 29, 2004. As a percentage of net sales, selling, general, and administrative expenses decreased 3.4 percentage points to 30.2% for the quarter ended August 28, 2005 compared with 33.6% for the quarter ended August 29, 2004. Contributing to the 3.4 percentage point decline were lower national advertising costs and lower fringe benefits. Also included in selling, general and administrative expenses for the quarter ended August 28, 2005 were gains of approximately $2.0 million on the disposal of our former facilities at Lake Wales, Florida and Memphis, Tennessee (which ceased operations in fiscal 2002 and 2001, respectively). In addition, the three months ended August 29, 2004 included a $4.0 million one time management bonus paid to the holders of Sealy Corporation stock options in lieu of the cash dividend which was paid to stockholders in association with our parent company's issuance of additional debt and equity in July of 2004.
30
Recapitalization Expense. The Company incurred approximately $0.4 million of additional recapitalization expenses in the quarter ended August 29, 2004 for the settlement of stock options and retention bonuses in connection with its merger with affiliates of Kohlberg Kravis Roberts & Co., L.P., completed April 6, 2004 (see Note 2 to the unaudited condensed consolidated financial statements included in Part I, Item 1 of this Quarterly Report).
Royalty Income, net of royalty expense. Royalty income, net of royalty expense, for the three months ended August 28, 2005 decreased $0.2 million over the three months ended August 29, 2004. This decrease was primarily due to higher royalty expense under the Pirelli licensing arrangement at our European subsidiary.
Interest Expense. Interest expense was approximately unchanged from the quarter ended August 29, 2004 as reductions due to lower average debt levels ($946.6 million average debt for the quarter ended August 28, 2005 versus $1,049.9 million for the quarter ended August 29, 2004) were offset by higher interest rates on the variable portion of our floating rate debt. Our weighted-average borrowing cost for the three months ended August 28, 2005 and August 29, 2004 was 7.3% and 6.6%, respectively.
Income Tax. Our effective tax rate for the three months ended August 28, 2005 and August 29, 2004 was 37.8% and 30.6%, respectively. Our effective income tax rate generally differs from the federal statutory rate due to the effects of certain foreign tax rate differentials and state and local income taxes. The effective rate for the quarter ended August 29, 2004 was also affected by certain non-deductible expenses associated with the recapitalization of April 4, 2004.
The following table sets forth our summarized results of operations for nine months ended August 28, 2005 and August 29, 2004 expressed in millions of dollars as well as a percentage of each year's net sales:
| | For the nine months ended
| |
---|
| | August 28, 2005
| | August 29, 2004
| |
---|
| | millions
| | percentage of net sales
| | millions
| | percentage of net sales
| |
---|
Total net sales | | $ | 1,104.9 | | 100.0 | % | $ | 992.0 | | 100.0 | % |
Total cost of goods sold | | | 612.8 | | 55.5 | | | 557.5 | | 56.2 | |
| |
| |
| |
| |
| |
Gross Profit | | | 492.1 | | 44.5 | | | 434.5 | | 43.8 | |
Selling, general and administrative | | | 336.7 | | 30.5 | | | 327.3 | | 33.0 | |
Recapitalization expense | | | — | | — | | | 133.1 | | 13.4 | |
Amortization of intangibles | | | 0.4 | | 0.0 | | | 0.9 | | 0.1 | |
Royalty income, net of royalty expense | | | (9.9 | ) | (0.9 | ) | | (10.6 | ) | (1.2 | ) |
| |
| |
| |
| |
| |
| Income from operations | | | 164.9 | | 14.9 | | | (16.2 | ) | (1.6 | ) |
Interest expense | | | 53.5 | | 4.8 | | | 51.2 | | 5.2 | |
Other (income) expense, net | | | 6.0 | | 0.5 | | | (0.9 | ) | (0.1 | ) |
| |
| |
| |
| |
| |
| Income before income taxes | | | 105.4 | | 9.5 | | | (66.5 | ) | (6.7 | ) |
Income taxes | | | 48.4 | | 4.4 | | | (16.0 | ) | (1.6 | ) |
| |
| |
| |
| |
| |
| Net income | | $ | 57.1 | | 5.2 | % | $ | (50.5 | ) | (5.1 | )% |
| |
| |
| |
| |
| |
Effective tax rate | | | 45.9 | % | | | | 24.1 | % | | |
31
The following table indicates the percentage distribution of our net sales in U.S. dollars throughout our international operations:
| | Nine Months Ended:
| |
---|
Geographic distribution of sales:
| | August 28, 2005
| | August 29, 2004
| |
---|
US Domestic | | 79.9 | % | 79.9 | % |
International: | | | | | |
| Canada | | 8.1 | | 8.1 | |
| Europe | | 7.1 | | 7.3 | |
| Mexico | | 1.6 | | 1.6 | |
| Other | | 3.3 | | 3.1 | |
| |
| |
| |
| | Total | | 100.0 | % | 100.0 | % |
| |
| |
| |
32
The following table shows our net sales and margin profitability for the major geographic regions of our operations, including local currency results for the significant international operations:
| | For the Nine Months Ended:
| |
---|
| | August 28 2005
| | August 29, 2004
| |
---|
| | millions
| | percentage of net sales
| | millions
| | percentage of net sales
| |
---|
Total Domestic (US Dollars): | | | | | | | | | | | |
| Total net sales | | $ | 883.2 | | 100.0 | % | $ | 793.0 | | 100.0 | % |
| Total cost of goods sold | | | 472.2 | | 53.5 | | | 433.0 | | 54.6 | |
| |
| |
| |
| |
| |
| | Gross profit | | | 411.0 | | 46.5 | | | 360.0 | | 45.4 | |
Total International (US Dollars): | | | | | | | | | | | |
| Total net sales | | | 221.7 | | 100.0 | | | 199.1 | | 100.0 | |
| Total cost of goods sold | | | 140.6 | | 63.4 | | | 124.5 | | 62.5 | |
| |
| |
| |
| |
| |
| | Gross profit | | | 81.1 | | 36.6 | | | 74.6 | | 37.5 | |
Canada: | | | | | | | | | | | |
| US Dollars: | | | | | | | | | | | |
| | Total net sales | | | 90.0 | | 100.0 | | | 80.6 | | 100.0 | |
| | Total cost of goods sold | | | 53.0 | | 58.9 | | | 47.6 | | 59.1 | |
| |
| |
| |
| |
| |
| | | Gross profit | | | 37.0 | | 41.1 | | | 33.0 | | 40.9 | |
| Canadian Dollars: | | | | | | | | | | | |
| | Total net sales | | | 110.3 | | 100.0 | | | 107.3 | | 100.0 | |
| | Total cost of goods sold | | | 64.8 | | 58.8 | | | 63.4 | | 59.1 | |
| |
| |
| |
| |
| |
| | | Gross profit | | | 45.5 | | 41.2 | | | 43.9 | | 40.9 | |
Europe: | | | | | | | | | | | |
| US Dollars: | | | | | | | | | | | |
| | Total net sales | | | 78.7 | | 100.0 | | | 72.0 | | 100.0 | |
| | Total cost of goods sold | | | 53.8 | | 68.4 | | | 47.1 | | 65.4 | |
| |
| |
| |
| |
| |
| | | Gross profit | | | 24.9 | | 31.6 | | | 24.9 | | 34.6 | |
| Euros: | | | | | | | | | | | |
| | Total net sales | | | 61.4 | | 100.0 | | | 58.9 | | 100.0 | |
| | Total cost of goods sold | | | 42.0 | | 68.4 | | | 38.4 | | 65.2 | |
| |
| |
| |
| |
| |
| | | Gross profit | | | 19.4 | | 31.6 | | | 20.5 | | 34.8 | |
Other International (US Dollars): | | | | | | | | | | | |
| Total net sales | | | 53.0 | | 100.0 | | | 46.4 | | 100.0 | |
| Total cost of goods sold | | | 33.8 | | 63.8 | | | 29.8 | | 64.2 | |
| |
| |
| |
| |
| |
| | Gross profit | | $ | 19.2 | | 36.2 | % | $ | 16.6 | | 35.8 | % |
Nine Months Ended August 28, 2005 compared with Nine Months Ended August 29, 2004
Net Sales. Net sales for the nine months ended August 28, 2005 were $1,104.9 million, an increase of $112.9 million, or 11.4% from the nine months ended August 29, 2004. Total domestic sales were $883.2 million for the first nine months of 2005 compared to $793.0 million for the first nine months of 2004. The domestic sales increase of $90.2 million was attributable to a 2.8% increase in volume and an 8.4% increase in average unit selling price. The increase in average unit selling price is due primarily to price increases announced in May 2004 to offset the effects of rising steel costs, and an improved sales
33
mix from our new UniCased® Posturepedic and TripLCased® Stearns & Foster lines as well as our new visco-elastic and latex foam specialty bedding products. Also, net sales for the first quarter of 2004 were reduced by the effects of close-out pricing on existing products in conjunction with the roll-out of our new Stearns & Foster product lines. Total international sales were $221.7 million for the nine months ended August 28, 2005 compared to $199.1 for the nine months ended August 29, 2004, an increase of $22.6 million, or 11.4%. This increase was significantly influenced by favorable exchange rate fluctuations, most notably in our European and Canadian markets, where local currency sales gains of 4.2% and 2.8%, respectively, translated into gains of 9.3% and 11.7%, respectively, in US Dollars. Local currency sales gains in our Canadian market were driven by a 7.4% increase in average unit selling price resulting from price increases implemented in response to increased material costs and the successful introduction of our UniCased® product line, partially offset by a 4.3% decrease in volume. Sales gains in the European market were primarily attributable to a 5.7% increase in volume, partially offset by a 1.4% decline in average unit selling price.
Cost of Goods Sold. Cost of goods sold for the nine months ended August 28, 2005, as a percentage of net sales, decreased 0.7 percentage points to 55.5%. Cost of goods sold for the domestic business, as a percentage of net sales, decreased 1.1 percentage points to 53.5%. This decrease (as a percentage of net sales) is due primarily to the increase in average unit selling price as discussed above, partially offset by increased material costs. On a per unit basis, material costs increased 15.5% relative to the first nine months of 2004 due primarily to increased steel and foam product costs as well as changes in the sales mix toward higher price-point products. Variable conversion costs, however, decreased 8.4% per unit, primarily due to increased manufacturing efficiency, lower health insurance costs, and lower product return costs. Domestic warranty costs were down approximately $2.4 million compared to the nine months ended August 29, 2004. This decrease is primarily due to approximately $2.7 million included in the provision for the nine months ended August 29, 2004 resulting from a change in estimate of the portion of product returns attributable to warranties, $1.1 million of other reserve adjustments in the quarter ended August 29, 2004 associated with 2003 and a decrease of $0.4 million in the amount of recoverable salvage included in the warranty obligation estimate. These items were partially offset by $0.5 million associated with a change in the third quarter of fiscal 2005 to the sales agreement with one of the Company's customers such that the customer is now allowed to return defective products, and $0.9 million due to increases in the average age of warranty claims. Previously, the customer received a discount in lieu of returning products. During 2004, we enhanced our data collection process with respect to warranty returns. This enhancement allows us to determine the age of the bed based on the manufacture date and allows us to specifically identify and track reasons for the return. This information has enabled us to improve the estimation process with respect to the estimated future warranty obligation and, more importantly, provides better management information with which we can isolate and remedy any causes for product defects. Because of the improved information, we believe this has improved our responsiveness to identified product defect issues which will likely result in claim trends more consistent with that of net sales. Cost of goods sold for the international business, as a percentage of net sales, increased 0.9 percentage points to 63.4%. This increase is primarily due to higher material costs and increased product return costs, partially offset by increased manufacturing efficiency in Canada associated with the new product lines and improved product mix in Argentina.
Selling, General, and Administrative. Selling, general, and administrative expenses increased $9.4 million to $336.7 million for the nine months ended August 28, 2005 compared to $327.3 million for the nine months ended August 29, 2004. As a percentage of net sales, selling, general, and administrative expenses were 30.5% and 33.0% for the nine months ended August 28, 2005 and August 29, 2004. Contributing to the 2.5 percentage point decline were lower national advertising costs and reduced provisions for customer utilization of promotional funds, a $1.4 million increase in foreign exchange transaction gains over the comparable nine months of 2004, and $2.2 million of gains during the fiscal 2005 nine month period on the disposal of assets held for sale. In addition, the nine months
34
ended August 29, 2004 included a $4.0 million one time management bonus paid to the holders of Sealy Corporation stock options in lieu of the cash dividend which was paid to stockholders in association with our parent company's issuance of additional debt and equity in July of 2004.
Recapitalization Expense. The Company incurred approximately $133.1 million of recapitalization expenses in the nine months ended August 29, 2004 in connection with its merger with affiliates of Kohlberg Kravis Roberts & Co., L.P., completed April 6, 2004 (see Note 2 to the unaudited condensed consolidated financial statements included in Part I, Item 1 of this Quarterly Report).
Royalty Income, net of royalty expense. Royalty income, net of expense, for the nine months ended August 28, 2005 decreased $0.7 million over the nine months ended August 29, 2004, primarily due to higher royalty expense under the Pirelli licensing arrangement at our European subsidiary.
Interest Expense. Interest expense for the nine months ended August 28, 2005 increased $2.3 million over the nine months ended August 29, 2004 primarily due to higher average debt levels resulting from the April 6, 2004 recapitalization as well as higher rates on the variable portion of our floating rate debt, partially offset by lower fixed interest rates. Our weighted-average borrowing cost for the nine months ended August 28, 2005 and August 29, 2004 was 7.4% and 7.8%, respectively.
Income Tax. Our effective tax rate for the nine months ended August 28, 2005 and August 29, 2004 was 45.9% and 24.1%, respectively. Our effective income tax rate generally differs from the federal statutory rate due to the effects of certain foreign tax rate differentials and state and local income taxes. For the nine months ended August 28, 2005, the rate was significantly increased due to the provision of approximately $7.2 million of income taxes on foreign earnings expected to be repatriated to the United States during fiscal 2005 (see Note 14 to the unaudited condensed consolidated financial statements included in Part I, Item 1 of this Quarterly Report). In the first nine months of 2004, the rate was affected by certain non-deductible expenses associated with the recapitalization.
Liquidity and Capital Resources
Our principal sources of funds are cash flows from operations and borrowings under our senior secured revolving credit facility. Our principal use of funds consists of operating expenditures, payments of principal and interest on our senior credit agreements, capital expenditures and interest payments on our outstanding senior subordinated notes. Capital expenditures totaled $19.8 million for the nine months ended August 28, 2005. We expect total 2005 capital expenditures to be approximately $25 million. We believe that annual capital expenditure limitations in our current debt agreements will not prevent us from meeting our ongoing capital needs. Our introductions of new products typically require us to make initial cash investments in inventory, promotional supplies and employee training which may not be immediately recovered through new product sales. However, we believe that we have sufficient liquidity to absorb such expenditures related to new products and that these expenses will not have a significant adverse impact on our operating cash flow. At August 28, 2005, we had approximately $80.1 million available under our revolving credit facility after taking into account letters of credit issued totaling $34.9 million. Our net weighted average borrowing cost was 7.4% and 7.8% for the nine months ended August 28, 2005 and August 29, 2004, respectively. The decline in our borrowing cost was due to lower rates on our new debt as compared with that retired in the April 2004 recapitalization and amendments to our senior credit facilities, partially offset by increases in the variable component of our floating rate debt.
35
As part of the April 2004 recapitalization we incurred substantial debt, including new senior credit facilities consisting of a $125 million senior secured revolving credit facility with a six-year maturity, and a $560 million senior secured term loan facility with an eight-year maturity. We also borrowed $100 million under a senior unsecured term loan, due in 2013, and issued $390 million aggregate principal amount of new Senior Subordinated Notes due 2014. Since the recapitalization and through August 28, 2005, we have repaid $150.0 million of the original $560.0 million outstanding under our senior secured term loan. Subsequent to the August 28, 2005 we have prepaid an additional $10 million of the senior secured term loan. By making such payments, we have effectively prepaid all principal payments due prior to the maturity of the loan in 2012. Most of the prepayments have been funded out of our operating cash flow, along with $10.0 million outstanding under our senior secured revolving credit facility at August 28, 2005. As of October 11, 2005, we have $8.5 million outstanding under our revolving credit facility.
Borrowings under our new senior secured credit facilities bear interest at our choice of the Eurodollar rate or adjusted base rate ("ABR"), in each case, plus an applicable margin, subject to adjustment based on a pricing grid. Annually, we may be required to make principal prepayments equal to 50% of excess cash flow for the preceding fiscal year, as defined in our senior secured credit agreement. At August 28, 2005, we estimate that there will be no such required prepayment due in the first quarter of fiscal 2006 due to the $60.0 million of voluntary prepayments made during the nine months ended August 28, 2005.
On April 14, 2005, we amended our senior secured credit agreement to provide for an additional $100 million of senior secured term borrowings. The proceeds from the additional borrowing were used to repay the $100 million outstanding under our senior unsecured term loan, effectively reducing the interest rate on this amount of debt by 275 basis points. The amendment also reduced the applicable interest rate margin charged on our senior secured term loan, provided certain financial leverage ratio tests are met. This amendment, along with a prior amendment on August 6, 2004, reduced the applicable margin by a total of 50 basis points. In addition, this amendment provides us with greater flexibility to make dividend distributions to our parent, Sealy Corporation, or to repay certain subordinated debt, provided certain leverage ratio tests and other conditions are met. The terms and conditions of the our $125 million senior revolving credit facility were unchanged by the amendment. In connection with the amendment, we incurred a charge of $6.2 million during the nine months ended August 28, 2005, including a non-cash charge of $3.3 million for the write-off of deferred finance charges primarily related to the senior unsecured term loan, $2.0 million of prepayment penalties related to the senior unsecured term loan, and $0.9 million of related fees and expenses.
On June 3, 2004, we entered into an interest rate swap agreement effective July 6, 2004 effectively fixing the floating portion of the interest rate at 3.725% on $200 million of the outstanding balance under the senior secured term loan through November 2005, declining to $150 million through November 2007. To retain the designation of this swap as a hedging instrument, we must select the Eurodollar rate on the hedged portion of the senior secured term loan during the term of the swap.
The outstanding Senior Subordinated Notes consist of $390 million aggregate principal amount maturing June 15, 2014, bearing interest at 8.25% per annum payable semiannually in arrears on June 15 and December 15, commencing on December 15, 2004. On September 29, 2004, we completed an exchange offer whereby all of the Senior Subordinated Notes were exchanged for publicly traded, registered securities with identical terms (other than certain terms relating to registration rights and certain interest rate provisions otherwise applicable to the original senior subordinated notes).
In August of 2005, we entered into a capital lease for the acquisition of computer equipment and software. The thirty-six month lease has annual mimimum rental payments of $0.5 million, and the net present value of the obligation at August 28, 2005 is $1.4 million (see Note 9 to the unaudited
36
condensed consolidated financial statements included in Part I, Item 1 of this Quarterly Report). Also, our European subsidiary expects to obtain financing of approximately $5.8 million related to capital expenditures of approximately $2.7 million in fiscal 2005 and $4.8 million in fiscal 2006.
At August 28, 2005 we were in compliance with the covenants contained within our senior credit agreements and note indenture.
As part of our ongoing evaluation of our capital structure, we continually assess opportunities to reduce our debt, which opportunities may from time to time include voluntary prepayments of our senior secured term debt, or redemption or repurchase of a portion of our senior subordinated notes to the extent permitted by our debt covenants.
Our ability to make scheduled payments of principal, or to pay the interest or liquidated damages, if any, on, or to refinance our indebtedness, or to fund planned capital expenditures will depend on our future performance, which, to a certain extent, is subject to general economic, financial, competitive, legislative, regulatory and other factors that are beyond our control. Based upon the current level of operations, we believe that cash flow from operations and available cash, together with available borrowings under the senior credit agreement, will be adequate to meet the future liquidity needs during the one year following August 28, 2005. We will be required to make scheduled principal payments of approximately $10.3 million during the next twelve months, substantially all of which is for debt owed by our international subsidiaries. However, as we continually evaluate our ability to make additional prepayments as permitted under our senior credit agreements, it is possible that we will make substantial prepayments on our senior debt during that time.
While we believe that we will have the necessary liquidity through our operating cash flow and revolving credit facility for the next several years to fund our debt service requirements, capital expenditures and other operational cash requirements, we may not be able to generate sufficient cash flow from operations, realize anticipated revenue growth and operating improvements or obtain future borrowings under the senior credit agreements in an amount sufficient to enable us to do so. In addition, the expiration of the revolving credit facility in 2010, followed by the maturities of the senior and subordinated debt in the following years through 2015, will likely require us to refinance such debt as it matures. We may not be able to effect any future refinancing of our debt on commercially reasonable terms or at all.
As discussed under "Foam Material Supply Shortages" above, the recent Gulf Coast hurricanes in late August and September of 2005 caused extensive damage to petrochemical processing facilities resulting in a temporary shortage of foam material used in the production of our bedding products. Due to this shortage, we anticipate temporary and limited impact on production schedules across all of our North American mattress plants for at least a portion of the fourth quarter of fiscal 2005. While the full duration and extent of the shortage remains unknown, we believe that by re-prioritizing our production and delivery schedules and utilizing our international operations to locate alternative sources of foam products we will be able to minimize the impact of this disruption. While we are unable at this time to quantify any potential adverse impact this disruption may have on our results of operations for the fourth quarter of fiscal 2005 or beyond, we do not anticipate a material adverse impact on our liquidity.
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The following table summarizes our changes in cash:
| | Nine Months Ended:
| |
---|
| | August 28, 2005
| | August 29, 2004
| |
---|
| | (in millions)
| |
---|
Statement of Cash Flow Data: | | | | | | | |
| Cash flows provided by (used in): | | | | | | | |
| | Operating activities | | $ | 63.8 | | $ | (19.4 | ) |
| | Investing activities | | | (10.0 | ) | | (3.6 | ) |
| | Financing activities | | | (48.2 | ) | | (59.4 | ) |
| Effect of exchange rate changes on cash | | | (0.4 | ) | | — | |
| |
| |
| |
| Change in cash and cash equivalents | | | 5.2 | | | (82.4 | ) |
| Cash and cash equivalents: | | | | | | | |
| | Beginning of period | | | 22.8 | | | 101.1 | |
| |
| |
| |
| | End of period | | $ | 28.0 | | $ | 18.7 | |
| |
| |
| |
Nine Months Ended August 28, 2005 Compared With Nine Months Ended August 29, 2004
Cash Flows from Operating Activities. Our cash flow from operations increased $83.2 million to $63.8 for the nine months ended August 28, 2005 compared to $(19.4) million for the nine months ended August 29, 2004. This improvement was primarily due to effects of the recapitalization on cash used in operating activities during the nine months ended August 29, 2004, which included approximately $90.7 million associated with recapitalization expenses, partially offset by higher cash interest payments of approximately $6.1 million during the nine months ended August 28, 2005
Cash Flows from Investing Activities. Our cash flows from investing activities decreased approximately $6.4 million to a net use of $10.0 million for the nine months ended August 28, 2005, compared with a net use of $3.6 million for the nine months ended August 29, 2004. Cash flows provided by investing activities during the 2004 period included $13.6 million of proceeds from the sale of a note receivable from an affiliate in connection with the recapitalization. Cash flows related to investment in property, plant and equipment included purchases and disposal proceeds of $19.8 million and $9.8 million, respectively, for the nine months ended August 28, 2005, and $18.7 million and $1.5 million, respectively, for the nine months ended August 29, 2004. Disposal proceeds in fiscal 2005 were primarily due to the sales of our Randolph, Massachusetts, Lake Wales, Florida, and Memphis, Tennessee facilities (which ceased operations in fiscal 2004, 2002 and 2001, respectively).
Cash Flows from Financing Activities. Our cash flow used in financing activities for the nine months ended August 28, 2005 decreased $11.2 million from the nine months ended August 29, 2004. Net cash used for fiscal 2004 financing activities was primarily the result of $35.2 million of debt issuance costs resulting from the recapitalization that were not funded with recapitalization proceeds, plus the voluntary prepayment of $25.0 million of our senior secured term debt during the third quarter. In fiscal 2005, cash used for financing activities included $60.0 million in voluntary prepayments of our senior secured term debt, offset by $4.8 million of net borrowings under our revolving credit facility and $7.0 million of borrowings by our European subsidiary.
Significant judgment is required in evaluating our federal, state and foreign tax positions and in the determination of our tax provision. Despite our belief that our tax return positions are fully
38
supportable, we have established reserves where we believe that certain tax positions are likely to be challenged and we may not fully prevail in overcoming these challenges. We may adjust these reserves as relevant circumstances evolve, such as guidance from the relevant tax authority, our tax advisors, or resolution of issues in the courts. Our tax expense includes the impact of reserve positions and changes to reserves that we consider appropriate, as well as related interest. Because we are not currently undergoing examinations of any of our corporate income tax returns by tax authorities, we believe that it is unlikely that an audit could be initiated which would result in assessment and payment of taxes related to these positions during the one year following August 28, 2005. We also cannot predict when or if any other future tax payments related to these tax positions may occur. Therefore, substantially all of the reserves for these positions are classified as noncurrent liabilities in our balance sheet.
We have evaluated the impact of the one-time favorable foreign dividend provisions enacted on October 22, 2004, as part of the American Jobs Creation Act of 2004, and determined that we qualify for certain favorable foreign withholding rates and may repatriate earnings of some of our foreign subsidiaries during the 2005 fiscal year. During the second fiscal quarter of 2005, we adopted the Dividend Reinvestment Plan ("DRP"). Under the DRP, we plan to repatriate $50 million pursuant to Section 965 of the 1986 Internal Revenue Code, as amended. There are no plans to repatriate foreign earnings after the close of the 2005 fiscal year. The estimated income tax liability associated with the repatriation is $7.2 million, which has been included in income tax expense for the nine months ended August 28, 2005. During the nine months ended August 28, 2005, we repatriated $25.1 million, net of $1.3 million withholding taxes.
Our long-term obligations contain various financial tests and covenants. The senior secured credit facilities require us to meet a minimum interest coverage ratio and a maximum leverage ratio. The indenture governing the senior subordinated notes also requires us to meet a fixed charge coverage ratio in order to incur additional indebtedness, subject to certain exceptions. We are currently in compliance with all debt covenants. The specific covenants and related definitions can be found in the applicable debt agreements, each of which has been previously filed with the Securities and Exchange Commission.
Certain covenants contained in the senior secured credit facilities and senior subordinated notes are based on what we refer to herein as "Adjusted EBITDA." In those agreements, EBITDA is defined as net income plus interest, taxes, depreciation and amortization and Adjusted EBITDA is defined as EBITDA further adjusted to exclude unusual items and other adjustments permitted in calculating covenant compliance. Adjusted EBITDA is presented herein as it is a material component of these covenants. For instance, the indenture governing the senior subordinated notes and the agreement governing the senior secured credit facilities of Sealy Mattress Company ("SMC") each contain financial covenant ratios, specifically leverage and interest coverage ratios, that are calculated by reference to Adjusted EBITDA. Non-compliance with the financial ratio maintenance covenants contained in SMC's senior secured credit facilities could result in the requirement to immediately repay all amounts outstanding under such facilities, while non-compliance with the debt incurrence ratios contained in the indenture governing the senior subordinated notes would prohibit SMC and its subsidiaries from being able to incur additional indebtedness other than pursuant to specified exceptions. In addition, under the restricted payment covenants contained in the indenture governing the senior subordinated notes, the ability of SMC to pay dividends is restricted by formula based on the amount of Adjusted EBITDA. While the determination of "unusual items" is subject to interpretation and requires judgment, we believe the adjustments listed below are in accordance with the covenants discussed above.
EBITDA and Adjusted EBITDA are not recognized terms under GAAP and do not purport to be alternatives to net income as a measure of operating performance or to cash flows from operating
39
activities as a measure of liquidity. Additionally, they are not intended to be measures of operating cash flows available for management's discretionary use, as they do not consider certain cash requirements such as interest payments, tax payments and debt service requirements. Because not all companies use identical calculations, these presentations may not be comparable to other similarly titled measures of other companies.
The following table sets forth a reconciliation of net income to EBITDA and EBITDA to Adjusted EBITDA:
| | Three months ended
| | Nine months ended
| |
---|
| | August 28, 2005
| | August 29, 2004
| | August 28, 2005
| | August 29, 2004
| |
---|
Net Income (loss) | | $ | 27.5 | | $ | 20.4 | | $ | 57.1 | | $ | (50.5 | ) |
| Interest cost | | | 17.3 | | | 17.3 | | | 53.5 | | | 51.2 | |
| Income taxes | | | 16.8 | | | 9.0 | | | 48.4 | | | (16.0 | ) |
| Depreciation and amortization | | | 5.7 | | | 6.1 | | | 16.4 | | | 18.3 | |
| |
| |
| |
| |
| |
EBITDA | | $ | 67.3 | | $ | 52.8 | | $ | 175.4 | | $ | 3.0 | |
| Recapitalization expenses | | | — | | | 0.4 | | | — | | | 133.1 | |
| Management fees to primary owner | | | 0.5 | | | 0.2 | | | 1.5 | | | 1.2 | |
| Unusual and nonrecurring losses: | | | | | | | | | | | | | |
| | Post-closing residual plant costs | | | (1.3 | ) | | 2.7 | | | (0.5 | ) | | 4.8 | |
| | Bank refinancing charge | | | — | | | — | | | 6.2 | | | — | |
| | Bonus to option holders related to parent company financing transaction | | | — | | | 4.0 | | | — | | | 4.0 | |
| | Other (various) | | | 0.7 | | | 0.2 | | | 0.3 | | | 5.7 | |
| |
| |
| |
| |
| |
Adjusted EBITDA | | $ | 67.2 | | $ | 60.3 | | $ | 182.9 | | $ | 151.8 | |
| |
| |
| |
| |
| |
Adjusted EBITDA for the trailing twelve month period ended August 28, 2005 used in our covenant calculations to determine compliance, was $231.0 million.
The following table sets forth a reconciliation of EBITDA to cash flow from operations:
| | Three months ended
| | Nine months ended
| |
---|
| | August 28, 2005
| | August 29, 2004
| | August 28, 2005
| | August 29, 2004
| |
---|
Net Income (loss) | | $ | 27.5 | | $ | 20.4 | | $ | 57.1 | | $ | (50.5 | ) |
| Interest cost | | | 17.3 | | | 17.3 | | | 53.5 | | | 51.2 | |
| Income taxes | | | 16.8 | | | 9.0 | | | 48.4 | | | (16.0 | ) |
| Depreciation and amortization | | | 5.7 | | | 6.1 | | | 16.4 | | | 18.3 | |
| |
| |
| |
| |
| |
EBITDA | | $ | 67.3 | | $ | 52.8 | | $ | 175.4 | | $ | 3.0 | |
Adjustments to EBITDA to arrive at cash flow from operations: | | | | | | | | | | | | | |
| Interest expense | | | (17.3 | ) | | (17.3 | ) | | (53.5 | ) | | (51.2 | ) |
| Income taxes | | | (16.8 | ) | | (9.0 | ) | | (48.4 | ) | | 16.0 | |
| Non-cash charges against (credits to) net income | | | 0.5 | | | (4.6 | ) | | 24.5 | | | 36.6 | |
| Changes in operating assets & liabilities | | | (4.6 | ) | | 3.8 | | | (34.2 | ) | | (23.8 | ) |
| |
| |
| |
| |
| |
Cash flow from operations | | $ | 29.1 | | $ | 25.7 | | $ | 63.8 | | $ | (19.4 | ) |
| |
| |
| |
| |
| |
40
"Safe Harbor" Statement Under the Private Securities Litigation Reform Act of 1995. When used in this Quarterly Report on Form 10-Q, the words "believes," "anticipates," "expects," "intends," "projects" and similar expressions are used to identify forward-looking statements within the meaning of the Private Securities Litigation Reform Act of 1995. Such forward-looking statements relate to future financial and operational results. Any forward-looking statements contained in this report represent our management's current expectations, based on present information and current assumptions, and are thus prospective and subject to risks and uncertainties which could cause actual results to differ materially from those expressed in such forward-looking statements. Actual results could differ materially from those anticipated or projected due to a number of factors. These factors include, but are not limited to:
- •
- the level of competition in the bedding industry;
- •
- legal and regulatory requirements;
- •
- the success of new products;
- •
- our relationships with our major suppliers;
- •
- fluctuations in costs of raw materials;
- •
- our relationship with significant customers and licensees;
- •
- our labor relations;
- •
- departure of key personnel;
- •
- encroachments on our intellectual property;
- •
- product liability claims;
- •
- the timing, cost and success of opening new manufacturing facilities;
- •
- our level of indebtedness;
- •
- interest rate risks;
- •
- future acquisitions;
- •
- an increase in return rates; and
- •
- other risks and factors identified from time to time in the Company's reports filed with the Securities and Exchange Commission.
All forward-looking statements attributable to us or persons acting on our behalf apply only as of the date of this Quarterly Report on Form 10-Q and are expressly qualified in their entirety by the cautionary statements include in this Quarterly Report on From 10-Q. Except as may be required by law, we undertake no obligation to publicly update or revise forward-looking statements which may be made to reflect events or circumstances after the date made or to reflect the occurrence of unanticipated events.
Item 3. Quantitative and Qualitative Disclosures About Market Risk
Information relative to the Company's market risk sensitive instruments by major category at November 28, 2004 is presented under Item 7a of the our Annual Report on Form 10-K for the fiscal year ended November 28, 2004.
41
Our earnings are affected by fluctuations in the value of our subsidiaries' functional currency as compared to the currencies of our foreign denominated purchases. Foreign currency forward, swap and option contracts are used to hedge against the earnings effects of such fluctuations. The result of a uniform 10% change in the value of the U.S. dollar relative to currencies of countries in which we manufacture or sell our products would not be material to our earnings or financial position. This calculation assumes that each exchange rate would change in the same direction relative to the U.S. dollar.
To protect against the reduction in value of forecasted foreign currency cash flows resulting from purchases in a foreign currency, we have instituted a forecasted cash flow hedging program. We hedge portions of our purchases denominated in foreign currencies with forward and option contracts. At August 28, 2005 we had forward contracts to sell a total of 30.5 million Canadian dollars with expiration dates ranging from September 2, 2005 through November 15, 2006. At August 28, 2005 the fair value of our net obligation under the forward contracts was $0.8 million. We do not designate our foreign currency hedges for accounting purposes, therefore all changes in fair value are charged to earnings.
As more fully discussed in Note 11 to our Condensed Consolidated Financial Statements (Part I, Item 1 included herein), we had entered into two interest rate swap agreements associated with debt existing prior to the April 2004 recapitalization. Although the related debt was repaid in connection with the recapitalization, the related swaps remain in effect and are scheduled to expire in December 2006. Because the first swap converted a portion of our floating rate debt to a fixed rate and a subsequent swap effectively re-established a floating rate on the same debt, the effect of the two instruments on both cash flows and earnings is largely off-setting. The combined fair value carrying amount of these swap instruments at August 28, 2005 and November 28, 2004 was a net obligation of $2.5 million and $4.3 million, respectively.
We had also entered into an interest rate cap agreement associated with previous debt that caps the floating rate on the debt at 8% through June 2005. The agreement also remains in effect following the repayment of the related debt. This agreement has not been designated for hedge accounting and, accordingly, any changes in the fair value are recorded in interest expense. The fair value of this instrument is not material.
On June 3, 2004, we entered into an interest rate swap agreement effective July 6, 2004 effectively fixing the floating portion of the interest rate at 3.725% on $200 million of our outstanding balance under the senior secured term loan through November 2005, declining to $150 million through November 2007. The fair value of this swap instrument was an asset of $1.9 million at August 28, 2005 and an obligation of $2.0 million at November 28, 2004.
A 10% increase or decrease in market interest rates that affect our interest rate derivative instruments would not have a material impact on our earnings during the next fiscal year.
Based on the unhedged portion of our variable rate debt outstanding at August 28, 2005, a 12.5 basis point increase or decrease in variable interest rates would have an approximately $0.4 million dollar impact on our annual interest expense.
The cost of our steel innerspring and our polyurethane foam and polyethylene component parts are impacted by volatility in the price of steel and petroleum. We expect the cost of the components to remain elevated above their recent historical averages throughout 2005. Thus far, we have been able to
42
successfully address these cost pressures through a price increase announced in May of 2004 and cost reduction efforts. We do not engage in commodity hedging programs.
See "Foam Material Supply Disruption" under Part I, Item 2 above regarding disruptions in the supply of foam products used in our bedding manufacturing process due to supplier shortages caused by recent hurricane damage on the Gulf Coast.
Item 4. Internal Control and Procedures
Under the supervision and with the participation of our management, including our principal executive officer and principal financial officer, we conducted an evaluation of the effectiveness of the design and operation of our disclosure controls and procedures, as defined in Rules 13a-15(e) and 15d-15(e) under the Securities Exchange Act of 1934, as amended, as of the end of the period covered by this report (the "Evaluation Date"). Based on this evaluation, our principal executive officer and principal financial officer concluded as of the Evaluation Date that our disclosure controls and procedures were effective such that the information relating to the Company, including our consolidated subsidiaries, required to be disclosed in our Securities and Exchange Commission ("SEC") reports (i) is recorded, processed, summarized and reported within the time periods specified in SEC rules and forms, and (ii) is accumulated and communicated to the Company's management, including our principal executive and principal financial officer, as appropriate to allow timely decisions regarding required disclosure.
In connection with the evaluation of our disclosure controls and procedures for the year ended November 28, 2004, and in connection with observations by our independent registered public accountants identified in their audit of our consolidated financial statements, management identified certain deficiencies in our financial statement close process primarily related to the review and approval process for various account analyses and reserve/accrual calculations and the consolidated financial/balance sheet review process. Management has discussed these deficiencies with our Audit Committee and we are currently addressing these deficiencies. Beginning with the financial statement close process for the first fiscal quarter of 2005, we instituted an enhanced management review and approval process for various reserves and accruals. In addition, we enhanced our balance sheet review procedures for the individual plant locations. The Company continued these enhanced procedures for the financial statement close process for the quarter ended August 28, 2005. We expect to continue improving the financial statement close process in 2005 as we continue to prepare for compliance with Section 404 of the Sarbanes-Oxley Act of 2002. Due to the recently announced one-year delay in the required compliance schedule for non-accelerated filers, we will be required to issue a management report on our assessment of internal controls over financial reporting in our Annual Report on Form 10-K for the year ended December 2, 2007. Should our parent company, Sealy Corporation, complete its proposed initial public offering of equity securities prior to June, 2006, we will be required to issue such report on internal controls for the year ended November 26, 2006.
There were no other changes in our internal control over financial reporting identified in connection with the foregoing evaluation that occurred during the third quarter of 2005 that have materially affected, or are reasonably likely to materially affect, our internal control over financial reporting.
43
PART II. OTHER INFORMATION
Item 1. Legal Proceedings.
See Note 16 to the Condensed Consolidated Financial Statements, Part I, Item 1 included herein.
Item 2. Unregistered Sales of Equity Securities and Use of Proceeds.
None
Item 3. Defaults Upon Senior Securities.
None
Item 4. Submission of Matters to a Vote of Security Holders
None
Item 5. Other Information.
None
Item 6. Exhibits
31.1 | | Chief Executive Officer Certification of the Quarterly Financial Statements |
31.2 | | Chief Financial Officer Certification of the Quarterly Financial Statements |
32 | | Certification Pursuant to 18 U.S.C. Section 1350 |
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SIGNATURES
Pursuant to the requirements of Section 13 or 15(d) of the Securities Exchange Act of 1934, Sealy Mattress Corporation has duly caused this report to be signed on its behalf by the undersigned, thereunto duly authorized.
| | SEALY MATTRESS CORPORATION |
Signature
| | Title
|
---|
/s/ DAVID J. MCILQUHAM David J. McIlquham | | Chief Executive Officer and President (Principal Executive Officer) |
/s/ JAMES B. HIRSHORN James B. Hirshorn | | Senior Executive Vice President—Finance Operations and Research and Development and Chief Financial Officer (Principal Accounting Officer) |
Date: October 12, 2005 | | |
45
QuickLinks
PART I. FINANCIAL INFORMATIONSEALY MATTRESS CORPORATION Condensed Consolidated Statements of Operations (in thousands) (unaudited)SEALY MATTRESS CORPORATION Condensed Consolidated Statements of Operations (in thousands) (unaudited)SEALY MATTRESS CORPORATION Condensed Consolidated Balance Sheets (in thousands) (unaudited)SEALY MATTRESS CORPORATION Condensed Consolidated Statements of Cash Flows (in thousands) (unaudited)SEALY MATTRESS CORPORATION Notes to Condensed Consolidated Financial StatementsSEALY MATTRESS CORPORATION Supplemental Consolidating Condensed Balance Sheet August 28, 2005 (in thousands)SEALY MATTRESS CORPORATION Supplemental Consolidating Condensed Balance Sheet November 28, 2004 (in thousands)SEALY MATTRESS CORPORATION Supplemental Consolidated Condensed Statements of Operations Three Months Ended August 28, 2005 (in thousands)SEALY MATTRESS CORPORATION Supplemental Consolidated Condensed Statements of Operations Three Months Ended August 29, 2004 (in thousands)SEALY MATTRESS CORPORATION Supplemental Consolidating Condensed Statements of Operations Nine Months Ended August 28, 2005 (in thousands)SEALY MATTRESS CORPORATION Supplemental Consolidating Condensed Statements of Operations Nine Months Ended August 29, 2004 (in thousands)SEALY MATTRESS CORPORATION Supplemental Consolidating Condensed Statements of Cash Flows Nine Months Ended August 28, 2005 (in thousands)SEALY MATTRESS CORPORATION Supplemental Consolidating Condensed Statements of Cash Flows Nine Months Ended August 29, 2004 (in thousands)SEALY MATTRESS CORPORATIONPART II. OTHER INFORMATIONSIGNATURES