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| BGC > SEC Filings for BGC > Form 10-K/A on 8-May-2009 | All Recent SEC Filings |
8-May-2009
Annual Report
Year Ended December 31,
(in millions) 2008 2007 2006
Net sales:
North America $ 2,178.7 $ 2,243.7 $ 2,058.6
Europe and North Africa 2,175.3 1,939.7 1,446.8
ROW 1,876.1 431.4 159.7
Total $ 6,230.1 $ 4,614.8 $ 3,665.1
Operating Income:
North America $ 122.5 $ 179.4 $ 128.9
Europe and North Africa 162.2 162.4 101.9
ROW 136.7 24.3 5.1
Total $ 421.4 $ 366.1 $ 235.9
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General Cable's reported net sales are directly influenced by the price of
copper, and to a lesser extent, aluminum. The price of copper and aluminum as
traded on the London Metal Exchange ("LME") and COMEX has historically been
subject to considerable volatility and, during the past few years, global copper
prices have established new average record highs as demonstrated in the table
above at Item 1 Raw Materials Sources and Availability.
General Cable generally passes changes in copper and aluminum prices along to
its customers, although there are timing delays of varying lengths depending
upon the volatility of metals prices, the type of product, competitive
conditions and particular customer arrangements. A significant portion of the
Company's electric utility and telecommunications business and, to a lesser
extent, the Company's electrical infrastructure business has metal escalators
included in customer contracts under a variety of price setting and recovery
formulas. The remainder of the Company's business requires that volatility in
the cost of metals be recovered through negotiated price changes with customers.
In these instances, the ability to change the Company's selling prices may lag
the movement in metal prices by a period of time as the customer price changes
are implemented. As a result of this and a number of other practices intended to
match copper and aluminum purchases with sales, profitability over time has
historically not been significantly affected by changes in copper and aluminum
prices. General Cable hedges metal purchases but does not engage in speculative
metals trading.
The Company has experienced volatility on raw materials other than copper and
aluminum used in cable manufacturing, such as insulating compounds, steel and
wood reels, freight costs and energy costs. Generally, the Company attempts to
adjust selling prices in most of its markets in order to offset the impact of
this raw material price and other cost volatility, particularly in periods of
rising costs. However, the Company's ability to ultimately realize price
increases, in periods of rising costs, is influenced by competitive conditions
in its markets, including manufacturing capacity utilization. In addition, a
sudden rise in raw material prices when combined with the normal lag time
between an announced customer price increase and its effective date in the
market, may result in the Company not fully recovering these increased costs. If
the Company were not able to adequately increase selling prices in a period of
rising raw material costs, the Company may experience a decrease in reported
earnings.
Current Business Environment
The wire and cable industry is competitive, mature and cost driven with minimal
differentiation for many product offerings among industry participants from a
manufacturing or technology standpoint. During recent years, the Company's end
markets have recovered from the previous low points of demand experienced in
2003; however beginning in the fourth quarter of 2007 and continuing throughout
2008, an economic slowdown in the United States and slowing growth in certain
European markets has resulted in lower demand during 2008 as compared to 2007.
In the past several years, there has been significant merger and acquisition
activity, which, the Company believes, has led to a reduction in inefficient,
high cost capacity in the industry.
In addition to the factors previously mentioned, General Cable is currently
being affected by the following macro-level trends:
• Slowing global growth and in many markets recessionary conditions;
• Weakness in demand for low-voltage electric utility products in North America and construction products in Europe, particularly as a result of the accelerated deterioration in the Spanish construction markets;
• Slowing demand and lower pricing across a broad spectrum of product lines in North America as a result of weak economic conditions and heightened competitive environment;
• Continued decline in demand for copper based telecommunication products;
• Continued political uncertainty and currency volatility in certain developing markets;
• Worldwide underlying long term growth trends in electric utility and infrastructure markets;
• Continuing demand for natural resources, such as oil and gas, and alternative energy initiatives; and
• Increasing demand for further deployment of submarine power and fiber optic communication systems.
The Company's overall financial results discussed in the following MD&A
demonstrate the diversification of the Company's product offering. In addition
to the aforementioned macro-level trends, the Company anticipates that the
following trends may affect the financial results of the Company during 2009.
The Company's working capital requirements have been and are expected to be
impacted by continued volatile raw materials costs, including metals and
insulating materials as well as freight and energy costs. Raw material costs,
particularly copper and aluminum prices, have been and will likely continue to
be volatile. Also, certain currencies around the world have been and are
anticipated to remain volatile, particularly in developing markets located in
certain countries in South America and Sub-Sahara Africa. Additionally, credit
markets in the United States and other regions around the world have grown
increasingly restrictive due to economic conditions and as a result access to
capital will need to be actively managed, as more fully discussed below.
As part of General Cable's ongoing efforts to reduce total operating costs, the
Company continuously evaluates its ability to more efficiently utilize existing
manufacturing capacity. Such evaluation includes the costs associated with and
benefits to be derived from the combination of existing manufacturing assets
into fewer plant locations and the possible outsourcing of certain manufacturing
processes. During 2006 and 2007, due to high utilization rates and strong
economic conditions, no facility closures occurred. However, during the fourth
quarter 2007, the Company rationalized outside plant telecommunication products
manufacturing capacity due to continued declines in telecommunications cable
demand. The Company closed a portion of its telecommunications capacity and
recorded a pre-tax charge to write-off certain production equipment of
$6.6 million. This action freed approximately 100,000 square feet of
manufacturing space to manufacture energy, industrial and construction cable
products for the Central and South American markets as well as the local Mexican
market. There were no facility closures during 2008.
General Cable believes its global investment in Lean Six Sigma ("Lean")
training, coupled with effectively utilized manufacturing assets, provides a
cost advantage compared to many of its competitors and generates cost savings
which help offset high raw material prices and other high general economic costs
over time. In addition, General Cable's customer and supplier integration
capabilities, one-stop selling and geographic and product balance are sources of
competitive advantage. As a result, the Company believes it is well positioned,
relative to many of its competitors, in the current business environment.
As more fully discussed below in the Liquidity and Capital Resources section,
the Company's current business environment encompasses credit markets in the
United States and in certain other regions around the world that have grown
increasingly restrictive. The Company has access to various credit facilities
around the world and believes that it can adequately fund its global working
capital requirements through both internal operating cash flow and use of the
various credit facilities. Overall, the capital structure changes made in the
recent years should allow the Company to maintain financial flexibility and a
lower average effective interest rate on outstanding debt when compared to prior
years. However, the Company anticipates upward pressure on interest rates on
certain of its credit facilities outside of North America at the time of renewal
in the coming year. Additionally, as a result of the significant and rapid
decline in metal prices beginning in September 2008, the Company's working
capital requirements are expected to be reduced resulting in significant
operating cash flow generation which has been partially offset by lower account
receivables and inventory values.
Acquisitions and Divestitures
General Cable actively seeks to identify key global macroeconomic and
geopolitical trends in order to capitalize on expanding markets and new niche
markets or exit declining or non-strategic markets in order to achieve better
returns. The Company also sets aggressive performance targets for its business
and intends to refocus or divest those activities, which fail to meet targets or
do not fit long-term strategies. The results of operations of the acquired
businesses discussed below have been included in the consolidated financial
statements since the respective dates of acquisition.
On June 30, 2008, the Company and its joint venture partner, A. Soriano
Corporation (Anscor), announced that the Company acquired and consolidated
Phelps Dodge Philippines (PDP) through an increase of its equity investment from
40% to 60%. The Company paid approximately $16.4 million (at prevailing exchange
rates) in cash to the sellers in consideration for the additional equity
interest in PDP and incurred insignificant fees and expenses related to the
transaction. PDP is a joint venture established in 1955 by Anscor, a Philippine
public holding company with diverse investments, and Phelps Dodge International
Corporation (PDIC), a subsidiary of the Company which was acquired in the fourth
quarter of 2007. PDP employs approximately 277 associates and operates one of
the largest wire and cable manufacturing facilities in the Philippines. The
investment complements the Company's strategy in the region by providing a
platform for further penetration into Southeast Asia markets as well as
supporting ongoing operations in Australia, the Middle East and South Africa. In
2007, the last full year before the purchase of additional equity ownership, PDP
reported net revenues of approximately $100 million. Net assets and pro forma
results of the PDP acquisition are immaterial.
On May 21, 2008, the Company entered a joint venture for majority ownership of
E.P.E / EN.I.CA.BISKRA/SPA (Enica Biskra), an Algerian state-owned manufacturer
of low and medium voltage power and construction cables. Enica Biskra employs
approximately 1,000 associates and is a leading provider of utility cables to
the principal Algerian state-owned power utility and gas producer. The Company
paid approximately $64.9 million in cash for its investment in Enica Biskra and
assumed existing debt of $43.0 million (at prevailing foreign currency exchange
rates on the date of purchase). Fees and expenses related to the acquisition
totaled approximately $1.0 million. In 2007, the last full year before the joint
venture was established, Enica Biskra reported net sales of approximately
$102.0 million (based on 2007 average exchange rates). Net assets and pro forma
results of the Enica Biskra acquisition are immaterial.
On October 31, 2007, the Company acquired the worldwide wire and cable business
of Freeport-McMoRan Copper and Gold, Inc., which operates as Phelps Dodge
International ("PDIC"), located principally in Latin America, sub-Saharan Africa
and Southeast Asia. PDIC has manufacturing, distribution and sales facilities in
19 countries and nearly 3,000 employees. With more than 50 years of experience
in the wire and cable industry, PDIC manufactures a full range of electric
utility, electrical infrastructure, construction and communication products. The
Company paid approximately $707.6 million in cash to the sellers in
consideration for PDIC and $8.5 million in fees and expenses related to the
acquisition. In 2006, the last full year before the acquisition, PDIC reported
global net sales of approximately $1,168.4 million (based on average exchange
rates). Certain pro forma information has been provided in Note 3 to the
Consolidated Financial Statements. Additionally, pro forma information and PDIC
audited financial statements were previously provided on Current Reports on Form
8-K/A filed on November 1, 2007 and amended on January 14, 2008.
On April 30, 2007, the Company acquired Norddeutsche Seekabelwerke GmbH & Co. KG
("NSW"), located in Nordenham, Germany from Corning Incorporated. As a result of
the transaction, the Company assumed liabilities in excess of the assets
acquired, including approximately $40.1 million of pension liabilities (based on
the prevailing exchange rate at April 30, 2007). The Company recorded proceeds
of $28.0 million, net of $0.8 million fees and expenses, which included $12.3
million of cash acquired and $5.5 million for settlement of accounts receivable.
NSW had revenues of approximately $120 million in 2006 (based on 2006 average
exchange rates) and has approximately 400 employees. NSW offers complete
solutions for submarine cable systems including manufacturing, engineering,
seabed mapping, project management, and installation for the offshore
communications, energy exploration, transmission, distribution, and alternative
energy markets. Pro forma results of the NSW acquisition are not material.
Critical Accounting Policies and Estimates
The Company's consolidated financial statements have been prepared in accordance
with accounting principles generally accepted in the United States of America. A
summary of significant accounting policies is provided in Note 2 to the
Consolidated Financial Statements. The application of these policies requires
management to make estimates and judgments that affect the amounts reflected in
the consolidated financial statements. Management bases its estimates and
judgments on historical experience, information that is available to management
about current events and actions the Company may take in the future and various
other factors that are believed to be reasonable under the circumstances. Actual
results may differ from these estimates under different assumptions or
conditions. The most critical judgments impacting the financial statements
include those policies described below. In addition, significant estimates and
judgments are also involved in the valuation allowances for sales incentives and
accounts receivable; warranty, uncertain tax positions, legal, environmental,
asbestos and customer reel deposit liabilities; assets and obligations related
to other postretirement benefits; and self-insured workers' compensation and
health insurance reserves. Management believes these judgments have been
materially accurate in the past and the basis for these judgments should not
change significantly in the future. Management periodically evaluates and
updates the estimates used in the application of its accounting policies,
adjusts amounts in the consolidated financial statements as necessary and has
discussed the development, selection and disclosure of these estimates with the
Audit Committee of the Company's Board of Directors.
Inventory Costing and Valuation
General Cable utilizes the LIFO method of inventory accounting for the majority
of its metals inventory. The Company's use of the LIFO method results in its
consolidated statement of operations reflecting the current costs of metals,
while metals inventories in the balance sheet are valued at historical costs as
the LIFO layers were created. If LIFO inventory quantities are reduced in a
period when replacement costs exceed the LIFO value of the inventory, the
Company would experience an increase in reported earnings. Conversely, if LIFO
inventory quantities are reduced in a period when replacement costs are lower
than the LIFO value of the inventory, the Company would experience a decline in
reported earnings. If the Company were not able to recover the LIFO value of its
inventory in some future period when replacement costs were lower than the LIFO
value of the inventory, the Company would be required to take a charge to
recognize in its consolidated statement of operations an adjustment of LIFO
inventory to market value.
The Company periodically evaluates the realizability of its inventory. In
circumstances where inventory levels are in excess of anticipated market demand,
where inventory is deemed to be technologically obsolete or not saleable due to
its condition or where inventory costs exceed net realizable value, the Company
records a charge to cost of sales and reduces the inventory to its net
realizable value.
Pension Accounting
General Cable provides retirement benefits through contributory and
non-contributory qualified and non-qualified defined benefit pension plans
covering eligible domestic and international employees as well as through
defined contribution plans and other postretirement benefits. Benefits under
General Cable's qualified U.S. defined benefit pension plan generally are based
on years of service multiplied by a specific fixed dollar amount, and benefits
under the Company's qualified non-U.S. defined benefit pension plans generally
are based on years of service and a variety of other factors that can include a
specific fixed dollar amount or a percentage of either current salary or average
salary over a specific period of time. The amounts funded for any plan year for
the qualified U.S. defined benefit pension plan are neither less than the
minimum required under federal law nor more than the maximum amount deductible
for federal income tax purposes. General Cable's non-qualified unfunded U.S.
defined benefit pension plans include a plan that provides defined benefits to
select senior management employees beyond those benefits provided by other
programs. The Company's non-qualified unfunded non-U.S. defined benefit pension
plans include plans that provide retirement indemnities to employees within the
Company's European business. Pension obligations for the non-qualified unfunded
defined benefit pension plans are provided for by book reserves and are based on
local practices and regulations of the respective countries. General Cable makes
cash contributions for the costs of the non-qualified unfunded defined benefit
pension plans as the benefits are paid.
Benefit costs for the defined benefit pension plans sponsored by General Cable
are determined based principally upon certain actuarial assumptions, including
the discount rate and the expected long-term rate of return on assets. The
weighted-average discount rate used to determine the net pension cost for 2008
was 6.00% for the U.S. defined benefit pension plans. The weighted-average
discount rate as of December 31, 2008 that was used to determine benefit
obligations was 5.75% for the U.S. defined benefit pension plans, and was
determined based on a review of long-term bonds that receive one of the two
highest ratings given by a recognized rating agency which are expected to be
available during the period to maturity of the projected pension benefit
obligations and based on information received from actuaries. The
weighted-average discount rate used to determine the net pension cost for 2008
was 5.76% for the non-U.S. defined benefit pension plans. Non-U.S. defined
benefit pension plans followed a similar evaluation process based on financial
markets in those countries where General Cable provides a defined benefit
pension plan, and the weighted-average discount rate used to determine benefit
obligations for General Cable's non-U.S. defined benefit pension plans was 5.91%
as of December 31, 2008. General Cable's expense under both U.S. and non-U.S.
defined benefit pension plans is determined using the discount rate as of the
beginning of the fiscal year, so 2009 expense for the defined benefit pension
plans will be based on the weighted-average discount rate of 5.75% for U.S.
plans and 5.91% for non-U.S. plans.
The weighted-average long-term expected rate of return on assets is assumed to
be 7.80% for 2009, reflecting an 8.50% weighted-average rate for the U.S. plans.
The weighted-average long-term expected rate of return on assets is based on
input from actuaries, including their review of historical 10-year, 20-year, and
25-year rates of inflation and real rates of return on various broad equity and
bond indices in conjunction with the diversification of the asset portfolio. The
expected long-term rate of return on assets for the qualified U.S. defined
benefit pension plan is based on an asset allocation assumption of 65% allocated
to equity investments, with an expected real rate of return of 8%, and 35% to
fixed-income investments, with an expected real rate of return of 2%, and an
assumed long-term rate of inflation of 3%. The actual asset allocations were 56%
of equity investments and 44% of fixed-income investments at December 31, 2008
and 64% of equity investments and 36% of fixed-income investments at
December 31, 2007. The expected long-term rate of return on assets of 6.7% for
qualified non-U.S. defined benefit plans is based on a weighted-average asset
allocation assumption of 52% allocated to equity investments, 44% to
fixed-income investments and 4% to other investments. The actual
weighted-average asset allocations were 49% of equity investments, 47% of
fixed-income investments and 4% of other investments at December 31, 2008 and
56% of equity investments, 40% of fixed-income investments and 4% of other
investments at December 31, 2007. Management believes that long-term asset
allocations on average and by location will approximate the Company's
assumptions and that the long-term rate of return used by each country that is
included in the weighted-average long-term expected rate of return on assets is
a reasonable assumption.
The determination of pension expense for the qualified defined benefit pension
plans is based on the fair market value of assets as of the measurement date.
Investment gains and losses are recognized in the measurement of assets
immediately. Such gains and losses will be amortized and recognized as part of
the annual benefit cost to the extent that unrecognized net gains and losses
from all sources exceed 10% of the greater of the projected benefit obligation
or the market value of assets.
General Cable evaluates its actuarial assumptions at least annually, and adjusts
them as necessary. The Company uses a measurement date of December 31 for all of
its defined benefit pension plans. In 2008, pension expense for the Company's
defined benefit pension plans was $8.2 million. Based on a weighted-average
expected rate of return on plan assets of 7.80%, a weighted-average discount
rate of 5.90% and various other assumptions, the Company estimates its 2009
pension expense for its defined benefit pension plans will increase
approximately $8.5 million from 2008. A 1% decrease in the assumed discount rate
would increase pension expense by approximately $1.8 million. Future pension
expense will depend on future investment performance, changes in future discount
rates and various other factors related to the populations participating in the
plans. In the event that actual results differ from the actuarial assumptions,
the funded status of the defined benefit pension plans may change and any such
change could result in a charge or credit to equity and an increase or decrease
in future pension expense and cash contributions.
Income Taxes
The Company provides for income taxes on all transactions that have been
recognized in the Consolidated Financial Statements in accordance with SFAS
No. 109. Under SFAS 109, deferred tax assets and liabilities are determined
based on the differences between the financial statement basis and tax basis of
assets and liabilities using enacted tax rates in effect for the year in which
the differences are expected to reverse. The effect of a change in tax rates on
deferred tax assets and liabilities is recognized in income in the period that
includes the enactment date.
The Company records a valuation allowance to reduce deferred tax assets to the
amount that it believes is more likely than not to be realized. The valuation of
the deferred tax asset is dependent on, among other things, the ability of the
Company to generate a sufficient level of future taxable income. In estimating
future taxable income, the Company has considered both positive and negative
evidence, such as historical and forecasted results of operations, including
prior losses, and has considered the implementation of prudent and feasible tax
planning strategies. At December 31, 2008, the Company had recorded a net
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