Note 13. Subsequent Event
On October 15, 2004, the date the Company completed its production requirements under the settlement agreement with General Motors and ceased operations at its Gastonia, North Carolina facility (see Note 3 – Goodwill and Intangible Assets and Note 9 - - Exit, Disposal, Certain Severance and Other Charges), in accordance with SFAS No. 144, Accounting for the Impairment or Disposal of Long Lived Assets, upon the abandonment of the facility in the fourth quarter of 2004, the operations of this business will be reclassified as discontinued operations.
Item 2. Management’s Discussion and Analysis of Financial Condition and Results of Operations
Forward-Looking Statement Notice
Readers are cautioned that certain statements contained in this Management’s Discussion and Analysis of Financial Condition and Results of Operations that are not related to historical results are “forward-looking statements” within the meaning of the Private Securities Litigation Reform Act of 1995. Statements that are predictive, that depend upon or refer to future events or conditions, or that include words such as “expects,” “anticipates,” “intends,” “plans,” “believes,” “estimates,” “hopes,” and similar expressions constitute forward-looking statements. In addition, any statements concerning future financial performance (including future revenues, earnings or growth rates), ongoing business strategies or prospects, and possible future Company actions are also forward-looking statements.
Forward-looking statements are based on current expectations, projections and assumptions regarding future events that may not prove to be accurate. Actual results may differ materially from those projected or implied in the forward-looking statements. Factors that could cause or contribute to such differences include, but are not limited to, dependence on significant customers, possible component parts shortages, the ability to achieve and manage growth, future indebtedness and liquidity, environmental matters, and competition. For a discussion of these and certain other factors, please refer to Item 1. ”Business - Certain Factors Affecting the Company” contained in our Annual Report on Form 10-K for the year ended December 31, 2003. Please also refer to our other filings with the Securities and Exchange Commission.
Critical Accounting Policies
Our financial statements are based on the selection and application of significant accounting policies, some of which require management to make estimates and assumptions regarding matters that are inherently uncertain. We believe that the following are the more critical judgment areas in the application of our accounting policies that currently affect our financial condition and results of operations.
Allowance for Doubtful Accounts. We maintain allowances for doubtful accounts for estimated losses resulting from the failure of our customers to make required payments. We evaluate the adequacy of our allowance for doubtful accounts and make judgments and estimates in determining the appropriate allowance at each reporting period. We perform ongoing credit evaluations of our customers and maintain sufficient allowances for potential credit losses. We evaluate the collectibility of our accounts receivable based on the length of time the receivable is past due and the anticipated future write-off based on historic experience. If a customer’s financial condition were to deteriorate, additional allowances could be required, which could have a material adverse impact on our financial statements.
16
Reserve for Inventory Obsolescence. We write down our inventory for estimated obsolescence or unmarketable inventory equal to the difference between the cost of the inventory and the estimated market value based upon assumptions about market conditions, future demand and expected usage rates. If actual market conditions are less favorable than those projected by management causing usage rates to vary from those estimated, additional inventory write-downs may be required, however these would not be expected to have a material adverse impact on our financial statements.
Warranty Liability. We provide an allowance for the estimated cost of product warranties at the time revenue is recognized. While we engage in extensive product quality programs and processes, including inspection and testing at various stages of the remanufacturing process and the testing of each finished assembly on equipment designed to simulate performance under operating conditions, our warranty obligation is affected by the number of products sold, historical and anticipated rates of warranty claims and costs per unit and actual product failure rates. Should actual product failure rates differ from our estimates, revisions to the estimated warranty liability may be required, although these would not be expected to have a material adverse impact on our financial statements.
Goodwill and Indefinite Lived Intangible Assets. Goodwill is tested for impairment annually, or more frequently if events or changes in circumstances indicate that goodwill may be impaired. Impairment is tested at the reporting unit level, a component of the operating segment as defined in paragraph 10 of SFAS No. 131, Disclosures about Segments of an Enterprise and Related Information. In estimating the fair value of our reporting units, we utilize a valuation technique based on multiples of projected cash flow, giving consideration to unusual items, cost reduction initiatives and other factors that generally would be considered in determining value. Actual results may differ from these estimates under different assumptions or conditions. If we were to lose a key customer within a particular operating segment or its revenues were to decrease materially, impairment adjustments that may be required could have a material adverse impact on our financial statements.
Results of Operations for the Three Month Period Ended September 30, 2004 Compared to the Three Month Period Ended September 30, 2003.
Income (loss) from continuing operations decreased $13.0 million, to a loss of $9.1 million for the three months ended September 30, 2004 from income of $3.9 million for the three months ended September 30, 2003. Our results for 2004 include a goodwill impairment charge of $13.6 million (net of tax) and exit, disposal, certain severance and other charges of $4.2 million (net of tax). For 2003, our results include exit, disposal, certain severance and other charges of $0.7 million (net of tax). Excluding these items, income from continuing operations increased primarily as a result of:
• the ramp-up of our Honda transmission remanufacturing program, AT&T Wireless test and repair program and other new business initiatives;
• benefits from our on-going lean and continuous improvement program and other cost reduction initiatives; and
• increases in our base logistics volume with AT&T Wireless;
partially offset by:
• price concessions provided to certain customers in our Drivetrain and Logistics segments as a result of negotiating and extending certain agreements in 2003;
17
• a reduction in volume due to the run-out of certain programs in our Logistics segment, including, the bulk collateral fulfillment program for AT&T Wireless Services (substantially completed during the third quarter of 2003), the material recovery and core qualification programs for Ford (substantially completed during the second and third quarters of 2003, respectively), and an OnStar telematics modification program for Delphi and General Motors;
• a reduction in GM remanufactured transmission volume coupled with costs related to our process improvement efforts geared toward the achievement of improved quality levels. GM subsequently decided to resource this business with alternative suppliers and these costs will not be incurred in the future.
Net Sales
Net sales increased $28.6 million, or 33.9%, to $112.9 million for the three months ended September 30, 2004 from $84.3 million for the three months ended September 30, 2003. This increase was primarily due to the ramp-up of our Honda transmission remanufacturing program, AT&T Wireless test and repair program and other new business initiatives, increases in our base logistics volume with AT&T Wireless and an increase in volume of Ford remanufactured transmissions, partially offset by:
• a reduction in volume due to the run-out of certain programs in the Logistics segment, including the bulk collateral fulfillment program for AT&T Wireless Services, the material recovery and core qualification programs for Ford, and an OnStar telematics modification program for Delphi and General Motors;
• price concessions provided to certain customers in our Drivetrain and Logistics segments as a result of negotiating and extending certain agreements in 2003; and
• a reduction in GM remanufactured transmission volume related to our process improvement efforts geared toward the achievement of improved quality levels. GM subsequently decided to resource this business with alternative suppliers and the remaining volume ($5.3 million in the third quarter of 2004) will be reduced to zero during the fourth quarter of 2004.
Of our revenues for the three months ended September 30, 2004 and 2003, Ford accounted for 28.6% and 35.5%, AT&T Wireless Services accounted for 20.5% and 16.9%, Honda accounted for 20.7% and 8.3%, DaimlerChrysler accounted for 12.3% and 17.9%, and General Motors accounted for 6.0% and 9.9%, respectively.
Gross Profit
Gross profit increased $3.6 million, or 16.3%, to $25.7 million for the three months ended September 30, 2004 from $22.1 million for the three months ended September 30, 2003. This increase was primarily the result of the factors described above under “Net Sales,” and benefits from our on-going lean and continuous improvement program and other cost reduction initiatives, partially offset by $3.0 million of disposal and other charges related to the termination of our GM drivetrain remanufacturing program in 2004 and costs related to our process improvement efforts geared toward the achievement of improved quality levels on GM remanufactured transmissions. Because of the termination of the GM program, these costs will not be incurred in the future. Gross profit as a percentage of net sales decreased to 22.8% for the three months ended September 30, 2004 from 26.2% for the three months ended September 30, 2003.
18
Selling, General and Administrative Expenses
Selling, general and administrative (“SG&A”) expense remained constant at $13.6 million for the three months ended September 30, 2004 and 2003. As a percentage of net sales, SG&A expense decreased to 12.1% for the three months ended September 30, 2004 from 16.1% for the three months ended September 30, 2003. The net impact is primarily the result of increased compensation expense related to our incentive compensation program (which was zero in 2003) and incremental business development costs in our Drivetrain segment, offset by benefits from our on-going lean and continuous improvement program and other cost reduction initiatives.
Exit, Disposal, Certain Severance and Other Charges.
During the three months ended September 30, 2004, we recorded $6.7 million ($4.2 million net of tax) of exit, disposal, certain severance and other charges including (i) $6.3 million related to the termination of our drivetrain remanufacturing program with General Motors and our decision to exit our facility located in Gastonia, North Carolina, which consists of $2.3 million of inventory write-downs (classified as Cost of Sales), $2.0 million of fixed asset impairment charges, $1.2 million for severance and related costs, $0.7 million of costs related to the termination of the contract with GM (classified as Cost of Sales) and $0.1 million of other costs to exit the facility, (ii) $1.4 million of non-cash stock-based compensation costs related to modifications to unexercised stock options previously granted to our former CFO, per the provisions of FASB Interpretation No. 44, Accounting for Certain Transactions Involving Stock Compensation (an Interpretation of APB Opinion No. 25) and (iii) $0.2 million of other costs, partially offset by a gain of $1.2 million related to the reversal of a previously established provision related to the Drivetrain Remanufacturing segment for a potential non-income state tax liability that has been reduced through the finalization of an audit by the state tax authorities.
During the three months ended September 30, 2003, we recorded $1.1 million ($0.7 million net of tax) of these costs, including (i) $0.9 million in our Drivetrain Remanufacturing segment related to the closure of our transmission remanufacturing facility located in Mahwah, New Jersey, consisting of $0.6 million of exit and other costs primarily associated with the relocation to the facility in Oklahoma City and $0.3 million for severance and related costs, (ii) $0.1 million of severance and related costs as part of a corporate cost reduction program and (iii) $0.1 million of exit and other costs associated with cost reduction activities in the Logistics segment.
We currently expect to record approximately $1.3 million of additional costs in the fourth quarter of 2004 related to the closure of our Gastonia facility.
As an on-going part of our planning process, we continue to identify and evaluate areas where cost efficiencies can be achieved through consolidation of redundant facilities, outsourcing functions or changing processes or systems. Implementation of any of these could require us to incur additional costs of a nature described above, which would be offset over time by the projected cost savings.
Impairment of Goodwill
During the three months ended September 30, 2004, we announced General Motors’ decision to resource its remanufactured transmission program from our facility located in Gastonia, North Carolina by the end of 2004 and our decision to close that facility. As a result, we recorded a charge of $22.1 million for the impairment of goodwill assigned to this reporting unit.
Income (Loss) from Operations
Income (loss) from operations decreased $21.0 million to a loss of $13.7 million for the three months ended September 30, 2004 from income of $7.3 million for the three months ended September 30, 2003. This decrease is primarily the result of the combination of factors described
19
above under “Impairment of Goodwill,” “Exit, Disposal, Certain Severance and Other Charges,” and “Gross Profit.”
Interest Expense
Interest expense decreased slightly to $1.8 million for the three months ended September 30, 2004 from $1.9 million for the three months ended September 30, 2003. This decrease was primarily due to a reduction in debt outstanding.
Income Tax Expense (Benefit)
Income tax expense (benefit) as a percentage of income (loss) from continuing operations increased to 38.5% for the three months ended September 30, 2004 from 37.0% for the three months ended September 30, 2003. Based on our current estimate of the distribution of taxable income by state, we expect our effective income tax rate for the balance of 2004 to remain at approximately 38.5%.
Reportable Segments
Drivetrain Remanufacturing Segment
The following table presents net sales and segment profit (loss) expressed in millions of dollars and as a percentage of net sales:
| | For the Three Months Ended September 30, | |
| | 2004 | | 2003 | |
Net sales | | $ | 79.6 | | 100.0 | % | $ | 60.5 | | 100.0 | % |
Segment profit before impairment of goodwill and exit, disposal, certain severance and other charges | | $ | 11.9 | | 14.9 | % | $ | 3.9 | | 6.4 | % |
Less: | | | | | | | | | |
Impairment of goodwill | | 22.1 | | | | — | | | |
Exit, disposal, certain severance and other charges | | 5.3 | | | | 0.9 | | | |
Segment profit (loss) | | $ | (15.5 | ) | — | | $ | 3.0 | | 5.0 | % |
Net Sales. Net sales increased $19.1 million, or 31.6%, to $79.6 million for the three months ended September 30, 2004 from $60.5 million for the three months ended September 30, 2003. The increase was primarily due to an increase in sales of remanufactured transmissions to Honda and to a lesser extent, Ford, partially offset by lower sales of remanufactured transmissions to DaimlerChrysler and General Motors. Sales to Honda increased $16.4 million, to $23.4 million for the three months ended September 30, 2004 from $7.0 million for the three months ended September 30, 2003, resulting from the continued ramp-up of the transmission remanufacturing program we launched in late 2002. We believe Honda has reached their targeted inventory positions for the transmission models we currently remanufacture and now expect future volumes to decline slightly from the levels achieved in the third quarter. Additionally, sales of remanufactured transmissions to General Motors of $5.3 million during the quarter will be eliminated during the fourth quarter due to GM’s decision to resource those products with other suppliers. Our GM production ceased on October 15, 2004.
20
Of our segment revenues for the three months ended September 30, 2004 and 2003, Ford accounted for 40.4% and 47.6%, Honda accounted for 29.4% and 11.5%, DaimlerChrysler accounted for 17.5% and 24.9%, and General Motors accounted for 7.1% and 11.8%, respectively.
Impairment of Goodwill. During the three months ended September 30, 2004, we announced General Motors’ decision to resource its remanufactured transmission program from our facility located in Gastonia, North Carolina by the end of 2004 and our decision to close that facility. As a result, we recorded a charge of $22.1 million for the impairment of goodwill assigned to this reporting unit.
Exit, Disposal, Certain Severance and Other Charges. During the three months ended September 30, 2004, we recorded a net charge of $5.3 million which included (i) $6.3 million related to the termination of our drivetrain remaunfacturing program with General Motors and our decision to exit our facility located in Gastonia, North Carolina consisting of $2.3 million of inventory write-downs, $2.0 million of fixed asset impairment charges, $1.2 million for severance and related costs, $0.7 million of costs related to the termination of the contract with GM and $0.1 million of other costs to exit the facility and (ii) $0.2 million of other costs, partially offset by a gain of $1.2 million related to the reversal of a previously established provision for a potential non-income state tax liability that has been reduced through the finalization of an audit by the state tax authorities.
During the three months ended September 30, 2003, we recorded special charges of $0.9 million related to the consolidation of our transmission remanufacturing facility located in Mahwah, New Jersey into our facility in Oklahoma City, Oklahoma comprised of $0.6 million of exit and other costs and $0.3 million for severance and related costs.
Segment Profit (Loss). Segment profit (loss) decreased $18.5 million to a loss of $15.5 million for the three months ended September 30, 2004 from income of $3.0 million for the three months ended September 30, 2003. Excluding the previously discussed costs of $27.4 million and $0.9 million recorded during 2004 and 2003, respectively, segment profit increased $8.0 million, or 205.1%, to $11.9 million (14.9% of segment net sales) for 2004 from $3.9 million (6.4% of segment net sales) for 2003. This resulted primarily from the factors described above under “Net Sales,” combined with benefits resulting from our lean and continuous improvement program and other cost reductions, partially offset by costs related to our process improvement efforts geared toward the achievement of improved quality levels on GM remanufactured transmissions. Because of the termination of the GM program, these costs will not be incurred in the future.
Logistics Segment
The following table presents net sales and segment profit expressed in millions of dollars and as a percentage of net sales:
| | For the Three Months Ended September 30, | |
| | 2004 | | 2003 | |
Net sales | | $ | 27.9 | | 100.0 | % | $ | 19.4 | | 100.0 | % |
Segment profit before exit, disposal, certain severance and other charges | | $ | 4.3 | | 15.4 | % | $ | 6.3 | | 32.5 | % |
Less: Exit, disposal, certain severance and other charges | | — | | | | 0.1 | | | |
Segment profit | | $ | 4.3 | | 15.4 | % | $ | 6.2 | | 32.0 | % |
Net Sales. Net sales increased $8.5 million, or 43.8%, to $27.9 million for the three months ended September 30, 2004 from $19.4 million for the three months ended September 30, 2003. This increase was primarily attributable to new business programs including our test and repair program
21
and other programs with AT&T Wireless Services (AWS) and our direct fulfillment and exchange programs with Cingular combined with an increase in our base AWS fulfillment business, partially offset by (i) a reduction in volume due to the run-out of the bulk collateral fulfillment program for AWS, the material recovery and core qualification programs for Ford, and an OnStar telematics modification program for Delphi and General Motors and (ii) a price reduction granted to AT&T Wireless Services in exchange for a long-term agreement. Sales to AT&T Wireless Services accounted for 83.2% and 73.1% of segment revenues for the three months ended September 30, 2004 and 2003, respectively.
Exit, Disposal, Certain Severance and Other Charges. During the three months ended September 30, 2003, we recorded charges of $0.1 million for termination benefits and exit and other costs associated with cost reduction activities in this segment.
Segment Profit. Segment profit decreased $1.9 million, or 30.6%, to $4.3 million (15.4% of segment net sales) for the three months ended September 30, 2004 from $6.2 million (32.0% of segment net sales) for the three months ended September 30, 2003. The decrease was primarily the result of the factors described above under “Net Sales,” partially offset by the benefits of our lean and continuous improvement program and other cost reductions.
Other
The following table presents net sales and segment loss expressed in millions of dollars and as a percentage of net sales:
| | For the Three Months Ended September 30, | |
| | 2004 | | 2003 | |
Net sales | | $ | 5.5 | | 100.0 | % | $ | 4.4 | | 100.0 | % |
Segment loss | | $ | (1.1 | ) | — | | $ | (1.8 | ) | — | |
Net Sales. Net sales increased $1.1 million, or 25.0%, to $5.5 million for the three months ended September 30, 2004 from $4.4 million for the three months ended September 30, 2003. This increase was primarily attributable to an increase in sales of remanufactured transmissions resulting from our initiative to penetrate the independent aftermarket, partially offset by a decrease in sales of remanufactured engines.
Segment Loss. Segment loss decreased $0.7 million, or 38.9%, to $1.1 million for the three months ended September 30, 2004 from $1.8 million for the three months ended September 30, 2003. The decreased loss was primarily the result of an increase in sales of remanufactured transmission coupled with benefits from our lean and continuous improvement program and other cost reduction initiatives.
Results of Operations for the Nine Month Period Ended September 30, 2004 Compared to the Nine Month Period Ended September 30, 2003.
Income (loss) from continuing operations decreased $20.3 million, to a loss of $0.1 million for the nine months ended September 30, 2004 from income of $20.2 million for the nine months ended September 30, 2003. Our results for 2004 include (i) a goodwill impairment charge of $13.6 million (net of tax), (ii) exit, disposal, certain severance and other charges of $6.4 million (net of tax) and (iii) an income tax benefit of $0.4 million related to the favorable resolution of an IRS audit of our 1999 tax year. For 2003, our results include exit, disposal, certain severance and other charges of $1.3 million (net of tax). Excluding these items, income from continuing operations decreased primarily as a result of:
22
• a reduction in volume due to the run-out of certain programs in our Drivetrain and Logistics segments including the bulk collateral fulfillment program for AT&T Wireless Services (substantially completed during the third quarter of 2003), the Kia transmission remanufacturing program (substantially completed during the second quarter of 2003), the material recovery and core qualification programs for Ford (substantially completed during the second and third quarters of 2003, respectively), and an OnStar telematics modification program for Delphi and General Motors;
• price concessions provided to certain customers in our Drivetrain and Logistics segments as a result of negotiating and extending certain agreements in 2003; and
• volume declines in our Drivetrain segment resulting from last year’s implementation by certain of our OEM customers of new policies governing repair-versus-replace decisions made by their dealers in warranty applications, which resulted in dealers replacing fewer transmissions with remanufactured units, a reduction in volume of DaimlerChrysler remanufactured transmissions resulting from DaimlerChrysler’s delayed launch of new model years into the remanufacturing program and a reduction in GM volume coupled with costs related to our process improvement efforts geared toward the achievement of improved quality levels and further inventory reductions at certain of our customers;
partially offset by:
• the ramp-up of our Honda transmission remanufacturing program, AT&T Wireless test and repair program and other new business initiatives;
• benefits from our on-going lean and continuous improvement program and other cost reduction initiatives; and
• an increase in our base logistics volume with AT&T Wireless.
Net Sales
Net sales increased $27.5 million, or 9.8%, to $307.0 million for the nine months ended September 30, 2004 from $279.5 million for the nine months ended September 30, 2003. This increase was primarily due to the ramp-up of our Honda transmission remanufacturing program, AT&T Wireless test and repair program and other new business initiatives and increases in our base logistics volume with AT&T Wireless, partially offset by:
• a reduction in volume due to the run-out of certain programs in our Drivetrain and Logistics segments including the bulk collateral fulfillment program for AT&T Wireless Services, the Kia transmission remanufacturing program, the material recovery and core qualification programs for Ford, and an OnStar telematics modification program for Delphi and General Motors;
• volume declines in our Drivetrain segment resulting from last year’s implementation by certain of our OEM customers of new policies governing repair-versus-replace decisions made by their dealers in warranty applications, which resulted in dealers replacing fewer transmissions with remanufactured units, a reduction in volume of DaimlerChrysler remanufactured transmissions resulting from DaimlerChrysler’s delayed launch of new model years into the remanufacturing program and a reduction in GM volume related to our process improvement efforts geared toward the achievement of improved quality levels; and
• price concessions provided to certain customers in our Drivetrain and Logistics segments as a result of negotiating and extending certain agreements in 2003.
Of our revenues for the nine months ended September 30, 2004 and 2003, Ford accounted for 29.0% and 35.8%, AT&T Wireless Services accounted for 19.1% and 16.0%, Honda accounted
23
for 18.1% and 5.7%, DaimlerChrysler accounted for 14.6% and 19.3% and General Motors accounted for 6.8% and 9.3%, respectively.
Gross Profit
Gross profit decreased $5.6 million, or 7.0%, to $74.0 million for the nine months ended September 30, 2004 from $79.6 million for the nine months ended September 30, 2003. During the nine months ended September 30, 2004 we recorded $3.0 million of disposal and other charges related to the termination of our GM drivetrain remanufacturing program and during the nine months ended September 30, 2003 we recorded $0.2 million of inventory write-downs related to the closure of our Mahwah, New Jersey facility. The decrease, excluding the charges, was primarily the result of the factors described above under “Net Sales” and costs related to our process improvements geared toward the achievement of improved quality levels on GM remanufactured transmissions, partially offset by benefits from our on-going lean and continuous improvement program and other cost reduction initiatives. Because of the termination of the GM program, these costs will not be incurred in the future. Gross profit as a percentage of net sales decreased to 24.1% for the nine months ended September 30, 2004 from 28.5% for the nine months ended September 30, 2003.
Selling, General and Administrative Expenses
SG&A expense increased $0.6 million, or 1.4%, to $42.0 million for the nine months ended September 30, 2004 from $41.4 million for the nine months ended September 30, 2003. The increase was primarily the result of compensation expense related to our incentive compensation program (which was zero in 2003), and growth support costs in our independent aftermarket and Drivetrain segment, partially offset by benefits from our on-going lean and continuous improvement program and other cost reduction initiatives. As a percentage of net sales, SG&A expense decreased to 13.7% for the nine months ended September 30, 2004 from 14.8% for the nine months ended September 30, 2003.
Exit, Disposal, Certain Severance and Other Charges.
During the nine months ended September 30, 2004, we recorded $10.4 million ($6.4 million net of tax) of exit, disposal, certain severance and other charges including (i) $6.3 million related to the termination of our drivetrain remanufacturing program with General Motors and our decision to exit our facility located in Gastonia, North Carolina, which consists of $2.3 million of inventory write-downs (classified as Cost of Sales), $2.0 million of fixed asset impairment charges, $1.2 million for severance and related costs, $0.7 million of costs related to the termination of the contract with GM (classified as Cost of Sales) and $0.1 million of other costs to exit the facility, (ii) $3.3 million of certain non-cash stock-based compensation costs related to modifications to unexercised stock options previously granted to our former CEO and CFO, per the provisions of FASB Interpretation No. 44, Accounting for Certain Transactions Involving Stock Compensation (an Interpretation of APB Opinion No. 25), (iii) $0.6 million of severance and related costs associated with the reorganization and upgrade of certain management functions and other cost reduction initiatives, (iv) $0.7 million of facility exit and other costs, (v) $0.5 million of certain non-cash stock-based compensation costs related to the hiring of our new CEO, and (vi) $0.2 million of relocation costs related to the hiring of our new CFO, partially offset by a gain of $1.2 million related to the reversal of a previously established provision related to the Drivetrain Remanufacturing segment for a potential non-income state tax liability that has been reduced through the finalization of an audit by the state tax authorities.
During the nine months ended September 30, 2003, we recorded $2.1 million ($1.3 million net of tax) of these costs, including (i) $1.8 million for our Drivetrain Remanufacturing segment related to the closure of our Mahwah facility, consisting of $1.1 million of exit and other costs primarily associated with the relocation to the facility in Oklahoma City, $1.0 million for severance and related costs, and $0.2 million of inventory write-downs (classified as a component of
24
Cost of Sales), partially offset by income of $0.5 related to the reversal of a special charge accrual established during 2001 for expected idle capacity costs at this plant, (ii) $0.2 million of severance and related costs as part of a corporate cost reduction program and (iii) $0.1 million of other exit and other costs associated with cost reduction activities in the Logistics segment.
We currently expect to record approximately $1.3 million of additional cost in the fourth quarter of 2004 related to the closure of our Gastonia facility.
As an on-going part of our planning process, we continue to identify and evaluate areas where cost efficiencies can be achieved through consolidation of redundant facilities, outsourcing functions or changing processes or systems. Implementation of any of these could require us to incur additional costs of a nature described above, which would be offset over time by the projected cost savings.
Impairment of Goodwill
During the nine months ended September 30, 2004, we announced General Motors’ decision to resource its remanufactured transmission program from our facility located in Gastonia, North Carolina by the end of 2004 and our decision to close that facility. As a result, we recorded a charge of $22.1 million for the impairment of goodwill assigned to this reporting unit.
Income from Operations
Income from operations decreased $33.6 million, to $2.4 million for the nine months ended September 30, 2004 from $36.0 million for the nine months ended September 30, 2003. This decrease is primarily the result of the combination of factors described above under “Impairment of Goodwill,” “Exit, Disposal, Certain Severance and Other Charges” And “Gross Profit.”
Interest Income
Interest income decreased $0.2 million, or 9.5%, to $1.9 million for the nine months ended September 30, 2004 from $2.1 million for the nine months ended September 30, 2003. This decrease was primarily due to our lower cash balances invested in cash and cash equivalents during 2004 as compared to 2003, as a result of the stock repurchases we made during 2004.
Interest Expense
Interest expense decreased $0.9 million, or 14.3%, to $5.4 million for the nine months ended September 30, 2004 from $6.3 million for the nine months ended September 30, 2003. This decrease was primarily due to a reduction in debt outstanding.
Income Tax Expense
During the nine months ended September 30, 2004, we recorded an income tax benefit of $0.4 million related to the favorable resolution of an IRS audit of our 1999 tax year. Based on our current estimate of the distribution of taxable income by state, we expect our effective income tax rate for the balance of 2004 to remain at approximately 38.5%.
Discontinued Operations
During the nine months ended September 30, 2004, we recorded a gain from discontinued operations of $1.4 million based upon the resolution of prior year income tax issues surrounding the tax basis of the Distribution Group, which business we sold in October 2000.
25
Reportable Segments
Drivetrain Remanufacturing Segment
The following table presents net sales and segment profit expressed in millions of dollars and as a percentage of net sales:
| | For the Nine months ended September 30, | |
| | 2004 | | 2003 | |
Net sales | | $ | 219.7 | | 100.0 | % | $ | 202.7 | | 100.0 | % |
Segment profit before impairment of goodwill and exit, disposal, certain severance and other charges | | $ | 28.5 | | 13.0 | % | $ | 22.3 | | 11.0 | % |
Less: | | | | | | | | | |
Impairment of goodwill | | 22.1 | | | | — | | | |
Exit, disposal, certain severance and other charges | | 5.8 | | | | 1.8 | | | |
Segment profit | | $ | 0.6 | | — | | $ | 20.5 | | 10.1 | % |
Net Sales. Net sales increased $17.0 million, or 8.4%, to $219.7 million for the nine months ended September 30, 2004 from $202.7 million for the nine months ended September 30, 2003. The increase was primarily due to an increase in sales to Honda of $39.6 million, to $55.5 million for the nine months ended September 30, 2004 from $15.9 million for the nine months ended September 30, 2003, resulting from the continued ramp-up of the transmission remanufacturing program we launched in late 2002, partially offset by:
• a reduction in volume of remanufactured transmissions sold to DaimlerChrysler, Ford and General Motors resulting from last year’s implementation of new policies governing repair-versus-replace decisions made by their dealers in warranty applications, which resulted in dealers replacing fewer transmissions with remanufactured units, a reduction in volume of DaimlerChrysler remanufactured transmissions resulting from DaimlerChrysler’s delayed launch of new model years into the remanufacturing program;
• the run out of the Kia transmission remanufacturing program;
• price concessions provided to certain customers as a result of negotiating and extending certain agreements; and
• a reduction in GM volume related to our process improvement efforts geared toward the achievement of improved quality levels.
Additionally, sales of remanufactured transmissions to General Motors of $16.4 million during the nine months ended September 30, 2004 will be eliminated during the fourth quarter due to GM’s decision to resource those products with other suppliers. Our GM production ceased on October 15, 2004.
Of our segment revenues for the nine months ended September 30, 2004 and 2003, Ford accounted for 40.3% and 46.6%, Honda accounted for 25.3% and 7.8%, DaimlerChrysler accounted for 20.4% and 26.6% and General Motors accounted for 7.8% and 10.3%, respectively.
Impairment of Goodwill. During the nine months ended September 30, 2004, we announced General Motors’ decision to resource its remanufactured transmission program from our facility located in Gastonia, North Carolina by the end of 2004 and our decision to close that
26
facility. As a result, we recorded a charge of $22.1 million for the impairment of goodwill assigned to this reporting unit.
Exit, Disposal, Certain Severance and Other Charges. During the nine months ended September 30, 2004, we recorded a net charge of $5.8 million including (i) $6.3 million related to the termination of our drivetrain remaunfacturing program with General Motors and our decision to exit our facility located in Gastonia, North Carolina, (ii) $0.4 million of costs primarily related to the termination of an independent contractor agreement and (iii) $0.3 million of severance and related costs primarily associated with the reorganization and upgrade of certain management functions and other cost reduction initiatives, partially offset by a gain of $1.2 million related to the reversal of a previously established provision for a potential non-income state tax liability that has been reduced through the finalization of an audit by the state tax authorities.
During the nine months ended September 30, 2003, we recorded a net charge of $1.8 million related to the decision to close of our transmission remanufacturing facility located in Mahwah, New Jersey, consisting of $1.0 million of severance and related costs, $1.1 million of exit and other costs primarily associated with the relocation to the facility in Oklahoma City, Oklahoma and $0.2 million of inventory write-downs partially offset by income of $0.5 related to the reversal of an accrual established during 2001 for expected idle capacity costs at the New Jersey plant.
Segment Profit. Segment profit decreased $19.9 million to $0.6 million for the nine months ended September 30, 2004 from $20.5 million for the nine months ended September 30, 2003. Excluding the previously discussed costs of $27.9 million and $1.8 million recorded during 2004 and 2003, respectively, segment profit increased $6.2 million, or 27.8%, to $28.5 million (13.0% of segment net sales) for 2004 from $22.3 million (11.0% of segment net sales) for 2003. This resulted primarily from the factors described above under “Net Sales,” combined with the benefits resulting from our lean and continuous improvement program and other cost reductions, partially offset by costs related to our process improvement efforts geared toward the achievement of improved quality levels on GM remanufactured transmissions. Because of the termination of the GM program, these costs will not be incurred in the future.
Logistics Segment
The following table presents net sales and segment profit expressed in millions of dollars and as a percentage of net sales:
| | For the Nine months ended September 30, | |
| | 2004 | | 2003 | |
Net sales | | $ | 72.0 | | 100.0 | % | $ | 63.8 | | 100.0 | % |
Segment profit before exit and certain severance charges | | $ | 10.7 | | 14.9 | % | $ | 20.4 | | 32.0 | % |
Less: Exit and certain severance charges | | 0.2 | | | | 0.2 | | | |
Segment profit | | $ | 10.5 | | 14.6 | % | $ | 20.2 | | 31.7 | % |
Net Sales. Net sales increased $8.2 million, or 12.9%, to $72.0 million for the nine months ended September 30, 2004 from $63.8 million for the nine months ended September 30, 2003. This increase was primarily attributable to new business programs including our test and repair program and other programs with AT&T Wireless Services (AWS) and our direct fulfillment and exchange programs with Cingular combined with an increase in our base AWS fulfillment business, partially offset by (i) a reduction in volume due to the run-out of the bulk collateral fulfillment program for AT&T Wireless Services, the material recovery and core qualification programs for Ford, and an OnStar telematics modification program for Delphi and General Motors and (ii) a price reduction granted to AT&T Wireless Services in exchange for a long-term agreement. Sales to AT&T
27
Wireless Services accounted for 81.4% and 70.0% of segment revenues for the nine months ended September 30, 2004 and 2003, respectively.
Exit and Certain Severance Charges. During the nine months ended September 30, 2004, we recorded $0.1 million of facility exit costs and $0.1 of severance and related costs associated with cost reduction initiatives.
During the nine months ended September 30, 2003, we recorded charges of $0.1 million of severance and related costs and $0.1 million of exit and other costs associated with cost reduction activities in the segment.
Segment Profit. Segment profit decreased $9.7 million, or 48.0%, to $10.5 million (14.6% of segment net sales) for the nine months ended September 30, 2004 from $20.2 million (31.7% of segment net sales) for the nine months ended September 30, 2003. The decrease was primarily the result of the factors described above under “Net Sales,” partially offset by the benefits of our lean and continuous improvement program and other cost reductions.
Other
The following table presents net sales and segment loss expressed in millions of dollars and as a percentage of net sales:
| | For the Nine months ended September 30, | |
| | 2004 | | 2003 | |
Net sales | | $ | 15.2 | | 100.0 | % | $ | 13.0 | | 100.0 | % |
Segment loss before exit charges | | $ | (4.2 | ) | — | | $ | (4.7 | ) | — | |
Less: Exit charges | | 0.1 | | | | — | | | |
Segment loss | | $ | (4.3 | ) | — | | $ | (4.7 | ) | — | |
Net Sales. Net sales increased $2.2 million, or 16.9%, to $15.2 million for the nine months ended September 30, 2004 from $13.0 million for the nine months ended September 30, 2003. This increase was primarily attributable to an increase in sales of remanufactured transmissions resulting from our initiative to penetrate the independent aftermarket, partially offset by a decrease in sales of remanufactured engines.
Exit Charges. During the nine months ended September 30, 2004, we recorded $0.1 million of facility exit costs in order to streamline certain operations.
Segment Loss. Segment loss decreased $0.4 million, or 8.5%, to a loss of $4.3 million for the nine months ended September 30, 2004 from a loss of $4.7 million for the nine months ended September 30, 2003. The reduced loss was primarily the result of an increase in sales of remanufactured transmissions coupled with benefits from our lean and continuous improvement program and other cost reduction initiatives, partially offset by an increase in SG&A expense associated with our initiative to penetrate the independent aftermarket for remanufactured transmissions.
Liquidity and Capital Resources
We had total cash and cash equivalents on hand of $8.8 million at September 30, 2004. Net cash provided by operating activities from continuing operations was $30.6 million for the nine-month period then ended. Net cash used in investing activities of $10.9 million for the period primarily related to manufacturing equipment additions to support the growth of our Honda remanufacturing program as well as cost reduction initiatives in both our Drivetrain and Logistics segments. Net cash used in financing activities of $70.5 million included $61.3 million for the
28
repurchase of our common stock for treasury, net payments of $7.4 million made on our credit facility, $4.2 million in payment of consideration related to previous acquisitions, and $0.3 million of payments on capital lease obligations offset by $2.7 million of proceeds from the exercise of stock options.
Capital expenditures for the nine months ended September 30, 2004 were $11.0 million and we expect to utilize an additional $3-4 million of capital expenditures for equipment purchases and facility improvements during the balance of 2004, for a total of approximately $14-15 million for the full year, primarily to support new business, capacity expansion and cost reduction initiatives in each of our businesses.
Our credit facility provides for (i) a $75.0 million, five-year term loan payable in quarterly installments in increasing amounts over the five-year period ($29.3 million outstanding at September 30, 2004), (ii) a $95.0 million, six-year, two-tranche term loan with approximately 97% of the outstanding balance payable in the sixth year ($83.2 million outstanding at September 30, 2004) and (iii) a $40.0 million, five-year revolving credit facility. Our credit facility also (i) includes an annual excess cash flow sweep payable as defined in the credit agreement and (ii) provides for the addition of one or more optional term loans of up to $100.0 million in the aggregate, subject to certain conditions (including the receipt from one or more lenders of the additional commitments that may be requested) and achievement of certain financial ratios.
At our election, amounts advanced under the credit facility will bear interest at either (i) the Alternate Base Rate plus a specified margin or (ii) the Eurodollar Rate plus a specified margin. The Alternate Base Rate is equal to the highest of (a) the lender’s prime rate, (b) the lender’s base CD rate plus 1.00% or (c) the federal funds effective rate plus 0.50%. The applicable margins for both Alternate Base Rate and Eurodollar Rate loans are subject to quarterly adjustments based on our leverage ratio as of the end of the four fiscal quarters then completed. As of September 30, 2004, the margins for the $75.0 million term loan and the $40.0 million revolving facility were 1.50% for Alternate Base Rate loans and 2.50% for Eurodollar Rate loans. For the $95.0 million term loan, the margins were 2.25% for Alternate Base Rate loans and 3.25% for Eurodollar Rate loans as of September 30, 2004.
As of September 30, 2004, our borrowing capacity under the revolving portion of our credit facility was $36.5 million.
As part of an ownership agreement we have for a 45% interest in an unconsolidated subsidiary, we have given the subsidiary’s bank a $0.9 million letter of credit in the event of the subsidiary’s default on outstanding debt.
As part of an earn-out related to the 1997 acquisition of ATS Remanufacturing, we have made payments of $4.0 million in 2004 ($1.0 million of which was made in April 2004 and $3.0 million of which was made in July 2004) and we will make a final payment of $2.4 million in January 2005. See Note 12. – Contingencies for a discussion of payments related to our ATS Remanufacturing acquisition and information regarding other contingencies.
Our revolving credit agreement with HSBC Bank Plc provides for £0.5 million, or $0.9 million in U.S. dollars, to finance the working capital requirements of our U.K. subsidiary. Amounts advanced are secured by substantially all the assets of our U.K. subsidiary. In addition, HSBC Bank may at any time demand repayment of all sums owing. Interest is payable monthly at the HSBC Bank prime lending rate plus 1.50%. As of September 30, 2004, there were no amounts outstanding under this line of credit.
As of December 31, 2003, we had approximately $27 million in federal loss carryforwards and approximately $18 million in state loss carryforwards available as an offset to future taxable income.
29
We believe that cash on hand, cash flow from operations and existing borrowing capacity will be sufficient to fund ongoing operations and budgeted capital expenditures. In pursuing future acquisitions, we will continue to consider the effect any such acquisition costs may have on liquidity. In order to consummate such acquisitions, we may need to seek funds through additional borrowings or equity financing.
Item 3. Quantitative and Qualitative Disclosures About Market Risk
Derivative Financial Instruments
We do not hold or issue derivative financial instruments for trading purposes. We have used derivative financial instruments to manage our exposure to fluctuations in interest rates. Neither the aggregate value of these derivative financial instruments nor the market risk posed by them has been material to our business. As of September 30, 2004, we were not using any derivative financial instruments.
Interest Rate Exposure
Based on our overall interest rate exposure during the nine months ended September 30, 2004, and assuming similar interest rate volatility in the future, a near-term (12 months) change in interest rates would not materially affect our consolidated financial position, results of operation or cash flows. A 10% change in the rate of interest would not have a material effect on our financial position, results of operation, cash flows or liquidity.
Foreign Exchange Exposure
We have one foreign operation that exposes us to translation risk when the local currency financial statements are translated to U.S. dollars. Since changes in translation risk are reported as adjustments to stockholders’ equity, a 10% change in the foreign exchange rate would not have a material effect on our financial position, results of operation or cash flows.
Item 4. Controls and Procedures
Our management, including Chief Executive Officer Donald T. Johnson, Jr. and Chief Financial Officer Todd R. Peters, have evaluated our disclosure controls and procedures as of the end of the quarter covered by this report. Under rules promulgated by the Securities and Exchange Commission, disclosure controls and procedures are defined as those “controls or other procedures of an issuer that are designed to ensure that information required to be disclosed by the issuer in the reports filed or submitted by it under the Exchange Act is recorded, processed, summarized and reported, within the time periods specified in the Commission’s rules and forms.” Based on the evaluation of our disclosure controls and procedures, management determined that such controls and procedures were effective as of September 30, 2004, the date of the conclusion of the evaluation.
There was no change in our internal control over financial reporting that occurred during the third quarter of 2004 that has materially affected, or is reasonably likely to materially affect, our internal control over financial reporting.
Further, there were no significant changes in the internal controls or in other factors that could significantly affect these controls after September 30, 2004, the date of the conclusion of the evaluation of disclosure controls and procedures.
30
AFTERMARKET TECHNOLOGY CORP.
Part II. Other Information
Item 2. Unregistered Sales of Equity Securities and Use of Proceeds
As a holding company with no independent operations, our ability to pay cash dividends is dependent upon the receipt of dividends or other payments from our subsidiaries. In addition, the agreement for our bank credit facility contains certain covenants that, among other things, place significant limitations on the payment of dividends.
Item 6. Exhibits and Reports on Form 8-K
(a) Exhibits
| 31.1 | | Rule 13a-14(a)/15d-14(a) Certification of Chief Executive Officer. |
| | | |
| 31.2 | | Rule 13a-14(a)/15d-14(a) Certification of Chief Financial Officer. |
| | | |
| 32.1 | | Section 1350 Certification of Chief Executive Officer. |
| | | |
| 32.2 | | Section 1350 Certification of Chief Financial Officer. |
(b) Reports on Form 8-K:
(1) Report dated July 28, 2004 reporting certain information under Item 12 and filing as an exhibit a press release containing such information.
(2) Report dated September 7, 2004 reporting information under Item 2.05 - Costs Associated with Exit or Disposal Activities and Item 2.06 - Material Impairments.
31
AFTERMARKET TECHNOLOGY CORP.
Signatures
Pursuant to the requirements of the Securities Exchange Act of 1934, the Registrant has duly caused this report to be signed on its behalf by the undersigned, thereunto duly authorized.
| | | AFTERMARKET TECHNOLOGY CORP. |
| | | |
| | | |
Date: | October 27, 2004 | | /s/ Todd R. Peters |
| | | Todd R. Peters, Vice President and Chief Financial Officer |
• Todd R. Peters is signing in the dual capacities as i) the principal financial officer, and ii) a duly authorized officer of the company.
32