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| RTI > SEC Filings for RTI > Form 10-K on 18-Feb-2009 | All Recent SEC Filings |
18-Feb-2009
Annual Report
Forward-Looking Statements
The following discussion should be read in connection with the information contained in the Consolidated Financial Statements and Notes to Consolidated Financial Statements. The following information contains "forward-looking statements" within the meaning of the Private Securities Litigation Reform Act of 1995, and is subject to the safe harbor created by that Act. Such forward-looking statements may be identified by their use of words like "expects," "anticipates," "intends," "projects," or other words of similar meaning. Forward-looking statements are based on expectations and assumptions regarding future events. In addition to factors discussed throughout this report, the following factors and risks should also be considered, including, without limitation,
• the effect of the slowdown in U.S and global economic activity and policy changes following the U.S. Presidential election,
• statements regarding the future availability and prices of raw materials,
• competition in the titanium industry,
• demand for the Company's products,
• the historic cyclicality of the titanium and commercial aerospace industries,
• changes in defense spending,
• the success of new market development,
• long-term supply agreements,
• the impact of Boeing 787 production delays,
• legislative challenges to the Specialty Metals Clause of the Berry Amendment,
• labor matters,
• outcome of the pending U.S. Customs investigation,
• the successful completion of our expansion projects,
• our ability to execute on new business awards,
• our order backlog and the conversion of that backlog into revenue, and
• other statements contained herein that are not historical facts.
Because such forward-looking statements involve risks and uncertainties, there are important factors that could cause actual results to differ materially from those expressed or implied by such forward-looking statements. These and other risk factors are set forth in this Annual Report on Form 10-K, as well as in our other filings with the Securities and Exchange Commission ("SEC") over the last 12 months, copies of which are available from the SEC or may be obtained upon request from the Company.
Overview
RTI International Metals, Inc. (the "Company," "RTI," "we," "us," or "our") is a leading U.S. producer and supplier of titanium mill products and a supplier of fabricated titanium and specialty metal parts for the global market.
Effective July 1, 2008, we introduced a new operating and financial reporting structure. Under the new structure, we separated our fabrication and distribution businesses into two segments in order to better position the Company to produce and offer customers a full range of value-added mill products, provide greater accountability for these individual operations, and drive increased transparency. As such, we now conduct our operations in three reportable segments: the Titanium Group, the Fabrication Group, and the Distribution Group.
The Titanium Group melts, processes, and produces a complete range of titanium mill products which are further processed by its customers for use in a variety of commercial aerospace, defense, and industrial and consumer applications. With operations in Niles, Ohio; Canton, Ohio; and Hermitage, Pennsylvania, the Titanium Group has overall responsibility for the production of primary mill products including, but not limited to, bloom,
billet, sheet, and plate. This Group also focuses on the research and development of evolving technologies relating to raw materials, melting and other production processes, and the application of titanium in new markets.
The Fabrication Group is comprised of companies with significant hard-metal expertise that extrude, fabricate, machine, and assemble titanium and other specialty metal parts and components. Its products, many of which are complex engineered parts and assemblies, serve commercial aerospace, defense, oil and gas, power generation, and chemical process industries, as well as a number of other industrial and consumer markets. With operations located in Houston, Texas; Washington, Missouri; Laval, Quebec; and a representative office in China, the Fabrication Group concentrates its efforts on maximizing its profitability by offering value-added products and services such as engineered tubulars and extrusions, fabricated and machined components and sub-assemblies, as well as engineered systems for energy-related markets by accessing the Titanium Group as its primary source of mill products.
The Distribution Group stocks, distributes, finishes, cuts-to-size, and facilitates just-in-time delivery services of titanium, steel, and other specialty metal products, primarily nickel-based specialty alloys. With operations in Garden Grove, California; Windsor, Connecticut; Houston, Texas; Indianapolis, Indiana; Sullivan, Missouri; Staffordshire, England; and Rosny-Sur-Seine, France; the Distribution Group services a variety of commercial aerospace, defense, and industrial and consumer customers.
Both the Fabrication and Distribution Groups access the Titanium Group as their primary source of mill products. Approximately 43%, 42%, and 43% of the Titanium Group's sales in 2008, 2007, and 2006, respectively, were to the Fabrication and Distribution Groups.
Approximately 50% of our sales in 2008 were directed to the commercial aerospace market. Air traffic demand, which drives new aircraft production along with aircraft titanium content, remained strong, and, not withstanding current global economic conditions, we believe that long-term demand for new aircraft should remain stable; especially with the increasing demand for air travel in the rising economic markets of Brazil, Russia, India, and China. The global demand for environmentally improved aircraft from both a noise pollution and fuel efficiency standpoint also supports the demand for the recently designed aircraft, including the Boeing 787 and Airbus A350XWB.
Over the past several years, through both our Fabrication group and our Distribution Group, we have focused much of our development activities and marketing initiatives on value-added titanium processing (i.e., engineering, designing, extruding, machining, and fabricating.) This focus positions us to be closer to the primary contractors as final systems integrators. As we move up the value chain, we become a more valuable supply partner. It also positions us to be less dependent on commodity titanium as our sole end product.
Like all titanium mill producers, a significant amount of our capital supports inventory, primarily work-in-process, which is driven by the nature of processing titanium to demanding metallurgical and physical specifications which often results in double or triple melting of the material. Further, as the Fabrication and Distribution Groups' businesses expand and their requirements for additional product from the Titanium Group grow, additional capital will be needed to support inventories. However, management is focused on reducing inventory levels and has dedicated additional resources to improve our internal supply chain management, resulting in a significant reduction in inventory during 2008. This is especially important in light of the continuing global economic uncertainties.
Much of our deployed capital relates to work-in-process inventory necessitated by the nature of processing titanium; however, significant investments in raw materials, such as titanium sponge and various master alloys, have also been made in an effort to secure an uninterrupted supply and to accommodate surges in demand. As a result, management has put in place various goals aimed at optimizing inventory levels and continually monitoring appropriate levels of required inventory.
Executive Summary
2008 was a challenging year, not only in the titanium industry, but also for our aerospace and energy customers. Our 2008 business plan was disrupted by the production delays for Boeing's new 787 Dreamliner, followed by a worldwide economic crisis that reduced the near-term demand for our products. Nonetheless, we finished the year with our third highest operating income ever, and our second highest year in revenues. Despite the
current global liquidity crisis, we ended the year with a strong balance sheet with over $284 million in cash and cash equivalents. During 2009, we intend to focus on balancing our cash needs and expenditures with the near and medium-term demand for our products and services.
Results of Operations
For the Year Ended December 31, 2008 Compared to the Year Ended December 31, 2007
Net Sales. Net sales for our reportable segments, excluding intersegment sales, for the years ended December 31, 2008 and 2007 are summarized in the following table:
Years Ended
December 31, $ Increase/ % Increase/
(In millions) 2008 2007 (Decrease) (Decrease)
Titanium Group $ 202.0 $ 253.1 $ (51.1 ) -20.2 %
Fabrication Group 146.8 132.0 14.8 11.2 %
Distribution Group 261.1 241.7 19.4 8.0 %
Total consolidated net sales $ 609.9 $ 626.8 $ (16.9 ) -2.7 %
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The decrease in the Titanium Group's net sales was primarily the result of a 20% decrease in average realized selling prices of prime mill products to trade customers due to changes in the sales mix between periods. During 2008, a higher percentage of our sales related to long-term supply agreements which generally carry lower overall sales prices and are subject to annual pricing adjustments. In addition, excess inventory in the market due to the announced Boeing 787 delays and the lower overall titanium demand profile resulted in lower spot market volume and lower realized selling prices.
The increase in the Fabrication Group's net sales was primarily related to an increase in shipments on our current long-term contracts in the commercial aerospace and defense markets, including increases in Boeing 787-related shipments, as well as better pricing on certain of our commercial aerospace programs and the completion of significant projects for our energy market customers.
The increase in the Distribution Group's net sales was primarily related to higher sales under our long-term supply agreement with Airbus supporting the Airbus family of commercial aircraft and higher demand from certain military programs. These increases were partially offset by a softening in realized prices for certain specialty metals products.
Gross Profit. Gross profit for our reportable segments for the year ended December 31, 2008 and 2007 are summarized in the following table:
Years Ended
December 31, $ Increase/ % Increase/
(In millions) 2008 2007 (Decrease) (Decrease)
Titanium Group $ 86.6 $ 121.4 $ (34.8 ) -28.7 %
Fabrication Group 31.4 28.1 3.3 11.7 %
Distribution Group 49.3 58.6 (9.3 ) -15.9 %
Total consolidated gross profit $ 167.3 $ 208.1 $ (40.8 ) -19.6 %
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Excluding the $0.8 million charge in 2008 and $7.2 million charge in 2007 associated with the U.S. Customs investigation of our previously filed duty drawback claims, gross profit for the Titanium Group decreased $41.2 million. The decrease in gross profit was primarily attributable to higher raw material costs and lower absorption of production costs, lower trade shipments volume, a lower margin product mix, and lower average realized selling prices in 2008 compared to 2007. These decreases were partially offset by favorable impacts associated with the sale of Titanium Group-sourced inventory by our Fabrication Group and Distribution Group businesses as well as favorable ferro-alloys margins in 2008.
The increase in gross profit for the Fabrication Group was largely due to increased sales across the commercial aerospace, defense, and energy markets, somewhat offset by lower utilization and other inefficiencies in the current
year related to delays in the ramp-up of the Boeing 787 Program. The gross profit percentage in 2008 of 21.4% slightly exceeded the 21.3% gross profit percentage in 2007.
The decrease in gross profit for the Distribution Group was primarily due to a decrease in realized prices for certain specialty metals that exceeded our decline in product cost and lower margins on certain military programs, coupled with an increase in lower margin shipments under our long-term supply agreements. As a result, gross profit percentage for the Distribution Group decreased to 18.8% in 2008 from 24.2% in 2007.
Selling, General, and Administrative Expenses. Selling, general, and administrative expenses ("SG&A") for our reportable segments for the years ended December 31, 2008 and 2007 are summarized in the following table:
Years Ended
December 31, $ Increase/ % Increase/
(In millions) 2008 2007 (Decrease) (Decrease)
Titanium Group $ 22.8 $ 17.3 $ 5.5 31.8 %
Fabrication Group 29.3 24.1 5.2 21.6 %
Distribution Group 25.7 23.9 1.8 7.5 %
Total consolidated SG&A $ 77.8 $ 65.3 $ 12.5 19.1 %
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The increase in SG&A was largely the result of increased compensation-related expenses, reflecting additional personnel and increased professional and consulting fees. These personnel include engineering and technology professionals to support long-term strategic growth projects and initiatives, including our announced expansion projects in Hamilton, Mississippi and Martinsville, Virginia. In addition, 2008 SG&A included the resolution of a commercial dispute with a customer that resulted in a bad debt write-off of $1.5 million and an employee benefit plan settlement charge of $2.0 million related to lump sum pension payments made in 2008 caused by two executives who retired in 2007.
Research, Technical, and Product Development Expenses. Total research, technical, and product development costs for the Company were $2.1 million in 2008 as compared to $1.7 million in 2007. This spending, primarily related to our Titanium Group, reflects the Company's continued efforts to make productivity and quality improvements to current manufacturing processes.
Operating Income. Operating income for our reportable segments for the year ended December 31, 2008 and 2007 are summarized in the following table:
Years Ended
December 31, $ Increase/ % Increase/
(In millions) 2008 2007 (Decrease) (Decrease)
Titanium Group $ 61.8 $ 102.6 $ (40.8 ) -39.8 %
Fabrication Group 2.0 3.5 (1.5 ) -42.9 %
Distribution Group 23.6 35.1 (11.5 ) -32.8 %
Total consolidated operating income $ 87.4 $ 141.2 $ (53.8 ) -38.1 %
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Excluding the $0.8 million charge in 2008 and $7.2 million charge in 2007 associated with the U.S. Customs investigation of our previously filed duty drawback claims, operating income for the Titanium Group decreased $47.2 million. This decrease was primarily the result of higher raw material costs and lower absorption of production costs, lower gross profit due to the lower margin product mix and lower average realized selling prices, coupled with higher SG&A costs primarily due to increased compensation-related expenses.
The decrease in operating income for the Fabrication Group was principally related to higher SG&A costs due to increases in compensation-related expenses and the settlement of a commercial dispute with a customer resulting in a bad debt write-off of $1.5 million. This increase in SG&A costs was offset to some extent by increased gross margin in our Fabrication Group due to increased sales across the commercial aerospace, defense, and energy markets.
The decrease in operating income for the Distribution Group was largely due to the continued softening in realized prices for certain specialty metals and lower margins on certain military programs, coupled with an increase in lower margin shipments under our long-term supply agreements and higher SG&A costs primarily due to increased compensation-related expenses.
Other Income (Expense). Other income (expense) increased to $1.5 million in 2008 as compared to $(2.1) million in the prior year. Other income (expense) consists mostly of foreign exchange gains and losses from our international operations, and was significantly impacted by the large fluctuations of the U.S. Dollar compared to the Canadian Dollar, the Euro, and the British Pound during 2008 compared to 2007. Our foreign currency exposure principally relates to the remeasurement of assets and liabilities of our international operations that are recorded in a currency other than the U.S. Dollar. Included in other income (expense) in 2007 was a gain of $1.0 million from the settlement of litigation against a former material supplier.
Interest Income and Interest Expense. Interest income decreased to $3.3 million in 2008 as compared to $4.8 million in the prior year. The decrease in interest income was principally related to lower returns on invested cash due to a more conservative investment philosophy in light of the continuing credit market uncertainties. This decrease was partially offset by an increase in our cash balances due to the funding received from our $225 million term loan during September 2008. The average effective rate earned in 2008 was 1.9% compared to 4.8% in 2007. Interest expense increased to $4.2 million in 2008 as compared to $1.3 million in the prior year. The increase in interest expense was primarily attributable to our increase in long-term debt compared to the prior year as a result of borrowing on our $225 million term loan in September 2008 to enhance our financial flexibility in anticipation of tightening credit markets.
Provision for Income Tax. We recognized income tax expense of $32.3 million, or 36.7% of pretax income in 2008 compared to $49.8 million, or 35.0% of pretax income, in 2007 for federal, state, and foreign income taxes. The $17.5 million decrease in tax expense is primarily attributable to lower U.S. income. The increase in the effective tax rate was primarily the result of changes in the relative mix of U.S. and foreign income, an absence of tax exempt investment income in 2008 that was present in 2007, and an increase in unrecognized tax benefits.
For the Year Ended December 31, 2007 Compared to the Year Ended December 31, 2006
Net Sales. Net sales for our reportable segments, excluding intersegment sales, for the years ended December 31, 2007 and 2006 are summarized in the following table:
Years Ended
December 31, $ Increase/ % Increase/
(In millions) 2007 2006 (Decrease) (Decrease)
Titanium Group $ 253.1 $ 204.9 $ 48.2 23.5 %
Fabrication Group 132.0 83.1 48.9 58.8 %
Distribution Group 241.7 217.4 24.3 11.2 %
Total consolidated net sales $ 626.8 $ 505.4 $ 121.4 24.0 %
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The Titanium Group's net sales increased by $48.2 million due to an increase in average selling prices driven by strong demand from the commercial aerospace markets offset by a slight decrease in trade shipments. The increases in selling price led to improved prime product sales of $71.2 million, offset by a slight decrease in volume of 364 thousand pounds, representing $7.4 million in trade sales. The Titanium Group's net sales were also impacted by decreases in trade sales from non-prime products, principally ferro-alloys, representing a $15.6 million decrease from the same period in the prior year.
The increase in the Fabrication Group's net sales of $48.9 million was primarily the result of continued strong demand from customers in most of the Group's businesses and product lines as well as increased selling prices. Although most of the increased sales were in the commercial aerospace market, we also completed significant projects for our energy market customers during 2007 that resulted in increased net sales of $10.1 million.
The increase in the Distribution Group's net sales was primarily related to higher sales under our long-term supply agreement with Airbus supporting the Airbus family of commercial aircraft and higher demand from certain military programs partially offset by a softening in realized selling prices for certain specialty metals.
Gross Profit. Gross profit for our reportable segments for the years ended December 31, 2007 and 2006 are summarized in the following table:
Years Ended
December 31, $ Increase/ % Increase/
(In millions) 2007 2006 (Decrease) (Decrease)
Titanium Group $ 121.4 $ 94.1 $ 27.3 29.0 %
Fabrication Group 28.1 28.0 0.1 0.4 %
Distribution Group 58.6 50.8 7.8 15.4 %
Total consolidated gross profit $ 208.1 $ 172.9 $ 35.2 20.4 %
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Excluding the $7.2 million charge associated with the U.S. Customs investigation of our previously filed duty drawback claims, gross profit for the Titanium Group increased by $34.5 million and gross profit percentage increased to 50.8% from 45.9% in the prior year. The increases in gross profit and gross profit percentage were primarily attributable to the increase in average selling prices driven by strong demand in the commercial aerospace markets.
The slight increase in gross profit for the Fabrication Group of $0.1 million was largely due to increased sales in all markets, as discussed above. The gross profit percentage for the Fabrication Group, however, decreased to 21.3% as compared to 33.7% in the prior year. The decrease in gross profit percentage was primarily due to startup costs relating to the new Claro facility, as we ramped-up to meet the demands of the Boeing 787 contract.
Gross profit for the Distribution Group increased to $58.6 million in 2007 from $50.8 million in 2006. The increase in gross profit was driven by overall increases in shipment volumes, as discussed above. Gross profit percentage also increased to 24.2% in 2007 from 23.4% in 2006 primarily due to new contract pricing.
Selling, General, and Administrative Expenses. SG&A for our reportable segments for the years ended December 31, 2007 and 2006 are summarized in the following table:
Years Ended
December 31, $ Increase/ % Increase/
(In millions) 2007 2006 (Decrease) (Decrease)
Titanium Group $ 17.3 $ 14.1 $ 3.2 22.7 %
Fabrication Group 24.1 20.4 3.7 18.1 %
Distribution Group 23.9 21.6 2.3 10.6 %
Total consolidated SG&A $ 65.3 $ 56.1 $ 9.2 16.4 %
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Total SG&A for the Company increased $9.2 million in 2007 compared to 2006. The increase in SG&A expenses primarily reflects increases in compensation-related expenses of $7.6 million. The increase largely reflects additional personnel to support business growth opportunities and one-time stock-based compensation and pension costs of $1.7 million related to the retirement of key executives. Increases related to other administrative expenses were offset by a decrease in audit and accounting fees of $2.7 million, principally due to improved efficiencies made in our Sarbanes-Oxley compliance program, and a decrease in bad debt expense.
Research, Technical, and Product Development Expenses. Total research, technical, and product development expenses were $1.7 million in 2007 compared to $1.5 million in 2006. This spending, primarily related to our Titanium Group, reflects the Company's continued efforts in making productivity and quality improvements to current manufacturing processes.
Operating Income. Operating income for our reportable segments for the years ended December 31, 2007 and 2006 are summarized in the following table:
Years Ended
December 31, $ Increase/ % Increase/
(In millions) 2007 2006 (Decrease) (Decrease)
Titanium Group $ 102.6 $ 78.5 $ 24.1 30.7 %
Fabrication Group 3.5 8.0 (4.5 ) -56.3 %
Distribution Group 35.1 28.8 6.3 21.9 %
Total consolidated operating income $ 141.2 $ 115.3 $ 25.9 22.5 %
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Excluding the $7.2 million charge associated with the U.S. Customs investigation of our previously filed duty drawback claims, operating income for the Titanium Group increased by $31.3 million and operating income percentage increased to 43.4% from 38.3% in the prior year. The increases in operating income and operating income percentage were largely attributable to the increase in average selling prices driven by strong demand in the commercial aerospace markets slightly offset by increased SG&A expenses.
The decrease in operating income for the Fabrication Group of $4.5 million reflects a slight gross margin improvement of $0.1 million largely offset by increased SG&A expenses related to additional personnel to support the Boeing 787 program. Operating income percentage for the Fabrication Group decreased . . .
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