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| WNC > SEC Filings for WNC > Form 10-K/A on 14-Aug-2009 | All Recent SEC Filings |
14-Aug-2009
Annual Report
including our customers, vendors and employees and could make it challenging and
difficult for us to raise additional debt or equity financing to the extent
needed, all of which could have a material adverse impact on our business,
results of operations and financial condition.
Strategic Alternatives
The Board of Directors has authorized management to pursue and evaluate a wide
range of strategic alternatives, including, but not limited to, select business
divestitures, changes to our capital structure, or a possible sale, merger or
other business combination. There can be no assurance that this evaluation will
result in any specific transaction.
Operating Performance
We measure our operating performance in four key areas - Safety/Environmental,
Quality, Productivity and Cost Reduction. Our objective of being better today
than yesterday and better tomorrow than we are today is simple, straightforward
and easily understood by all our associates.
• Safety/Environmental. We have made improvements to our total recordable
incident rate resulting in a 5% reduction in our workers compensation costs
in 2008 compared to 2007. We maintain ISO 14001 registration of our
Environmental Management System. We believe that our improved
environmental, health and safety management translates into higher labor
productivity and lower costs as a result of less time away from work and
improved system management.
• Quality. We monitor product quality on a continual basis through a number of means for both internal and external performance as follows:
- Internal performance. Our primary internal quality measurement is Process Yield (PY). PY is a performance metric that measures the impact of all aspects of the business on our ability to ship trailers at the end of the production process. In 2008, quality expectations were increased while maintaining PY performance and reducing rework.
- External performance. We actively measure and track our warranty claims and costs. Early life cycle warranty claims are trended for performance monitoring and have shown a steady improvement from an average of approximately 6 claims per 100 trailers in 2005 to 3 claims per 100 trailers in 2008. This information is utilized, along with other data, to drive continuous improvement initiatives relative to product quality and reliability. Through these efforts, we continue to realize improved quality, which has resulted in a sustained decrease for warranty payments over the past four years.
• Productivity. We measure productivity on many fronts. Some key indicators include production line speed, man-hours per trailer and inventory levels. Improvements over the last several years in these areas have translated into significant improvements in our ability to better manage inventory flow and control costs.
• Cost Reduction. We believe Continuous Improvement (CI) is a fundamental component of our operational excellence focus. In 2008, we focused on productivity enhancements within manufacturing assembly and sub-assembly areas through developing the capability for mixed model production. We also established a central warehousing and distribution center to improve material flow, inventory levels and inventory accuracy within our supply chain. The final components of the warehousing consolidation project were completed in the end of the first quarter 2009, thus realizing significant savings in the supply chain operation. We deployed value engineering and analysis teams to improve product and process costs thus keeping us competitive in the marketplace. In 2008, we also took actions to reduce costs by temporarily slowing down production at some of our facilities, extending normal shutdown periods and reducing salaried headcount levels. We deployed an operational excellence strategy to enhance a culture of daily continuous improvement. We believe the improvements generated to date provide the flexibility needed to support our customers as well as provide the foundation for enhanced performance going forward.
Industry Trends
Truck transportation in the U.S., according to the ATA, was estimated to be a
$650 billion industry in 2008, representing about 5% of U.S. Gross Domestic
Product. ATA estimates that approximately 70% of all freight tonnage is carried
by trucks at some point during its shipment. Trailer demand is a direct function
of the amount of freight to be transported. To monitor the state of the
industry, we evaluate a number of indicators related to trailer manufacturing
and the transportation industry. Recent trends we have observed include the
following:
• Transportation / Trailer Cycle. Transportation, including trucking, is a
cyclical industry that has experienced three cycles over the last 20 years.
Truck freight tonnage, according to ATA statistics, has been negative
year-over-year from mid 2006 through most of 2007. Even though tonnage
volumes increased 0.7% year-over-year in 2008, recent data shows further
weakening of freight tonnage. The trailer industry generally precedes
transportation industry cycles. The current cycle began in early 2001 when
industry shipments totaled approximately 140,000, reached a peak in 2006
with shipments of approximately 280,000 and, based on current ACT
estimates, is expected to reach the bottom in 2009. According to ACT,
shipments in 2008 amounted to approximately 144,000 units and will be
approximately 76,000 and 136,000 in 2009 and 2010, respectively. Our view
is generally consistent with that of ACT.
• Age of Trailer Fleets. During the three-year period ending December 31, 2007 (the latest such information available), the average age of the top 11 publicly traded truckload motor carrier trailer fleets increased from 4.5 years to 5 years. However, the average age of the total population during this same period remained relatively unchanged at approximately 7 years, increasing to 7.5 years for 2008. The stability of overall fleet age suggests a replacement demand estimated at 185,000 per year.
• New Trailer Orders. According to ACT, quarterly industry order placement rates have experienced year-over-year declines in each of the last nine quarters through the quarter ended December 31, 2008. Total trailer orders in 2008 were 112,000 units, a 34% decrease from the 170,000 units ordered in 2007.
• Other Developments. Other developments and our view of their potential impact on the industry include:
- U.S. federal truck emission regulations took effect on January 1, 2007, resulting in cleaner, yet less fuel-efficient and more costly tractor engines. Trucking companies accelerated purchases of tractors prior to the effective date of the regulation, significantly reducing the historical trailer-to-tractor ratio. In 2010, additional emission regulations are scheduled to take effect which may result in reoccurrence of accelerated truck purchases, again reducing the trailer-to-tractor ratio. We believe that on average the trailer-to-tractor ratio is unlikely to return to prior historic norms.
- Continuing improvements in trailer quality and durability resulting from technological advances like DuraPlateâ composite, as well as increased trailer utilization due to growing adoption of trailer tracking could result in reduced trailer demand.
- Trucking company profitability, which can be influenced by factors such as fuel prices, freight tonnage volumes, and government regulations, is highly correlated with the overall economy of the U.S. Decreases in trucker profitability reduce the demand for, and financial ability to purchase, new trailers.
- Truck driver shortages experienced over the past several years have constrained and are expected to continue to constrain freight market capacity growth. As a result, trucking companies are under increased pressure to look for alternative ways to move freight, leading to more intermodal freight movement. We believe that railroads are at or near capacity, which will limit their ability to grow. We therefore expect that the majority of freight will still be moved by truck.
Results of Operations
The following table sets forth certain operating data as a percentage of net
sales for the periods indicated:
Years Ended December 31,
2008 2007 2006
(Percentage of Net Sales)
Net sales 100.0 % 100.0 % 100.0 %
Cost of sales 97.5 91.7 92.0
Gross profit 2.5 8.3 8.0
General and administrative expenses 5.3 4.5 4.0
Selling expenses 1.7 1.4 1.1
Impairment of goodwill 7.9 - 1.2
(Loss) Income from operations (12.4 ) 2.4 1.7
Interest expense (0.6 ) (0.5 ) (0.5 )
Foreign exchange, net - 0.3 -
(Loss) Income before income taxes (13.0 ) 2.2 1.2
Income tax expense 2.0 0.7 0.5
Net (loss) income (15.0 )% 1.5 % 0.7 %
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2008 Compared to 2007
Net Sales
Net sales in 2008 were $836.2 million, a decrease of $266.3 million, or 24.2%,
compared to 2007. By business segment, net external sales and related units sold
were as follows (dollars in millions):
Year Ended December 31,
2008 2007 % Change
Sales by Segment
Manufacturing $ 694.2 $ 952.8 (27.1 )
Retail and Distribution 142.0 149.7 (5.1 )
Total $ 836.2 $ 1,102.5 (24.2 )
New Trailers (units)
Manufacturing 30,800 43,400 (29.0 )
Retail and Distribution 2,500 3,000 (16.7 )
Total 33,300 46,400 (28.2 )
Used Trailers 6,600 4,400 50.0
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Manufacturing segment sales for 2008 were $694.2 million, a decrease of
$258.6 million, or 27.1%, compared to 2007. Due to a continued weak market
demand and declines in the housing and construction markets, new trailer sales
decreased 12,600 units, or approximately $269.7 million. Higher average selling
prices impacted sales by $16.1 million in efforts to offset material price
increases.
Retail and distribution segment sales were $142.0 million in 2008, a decrease of
$7.7 million, or 5.1%, compared to 2007. New trailer sales decreased
$3.9 million, or 5.4%, compared to 2007 due to lower volumes primarily as a
result of the overall decline in the U.S. market. Used trailer sales were flat
compared to the prior year
as higher volumes were offset by lower average selling prices as depressed
market conditions have driven used trailer values down throughout 2008. Parts
and service sales were $37.1 million in 2008, a decrease of $3.5 million, or
8.6%, compared to 2007 due to continued weak customer demand.
Cost of Sales
Cost of Sales in 2008 was $815.3 million, a decrease of $195.5 million, or
19.3%, compared to 2007. As a percentage of net sales, cost of sales was 97.5%
in 2008 compared with 91.7% in 2007.
Manufacturing segment cost of sales was $680.4 million in 2008, a decrease of
$189.6 million, or 21.8%, compared to 2007. As a percentage of net sales, cost
of sales was 98.0% in 2008 compared to 91.3% in 2007. Cost of sales for our
manufacturing business segment for the years ending December 31, 2008 and 2007
were as follows (dollars in millions):
2008 2007
Manufacturing Segment % of Rev % of Rev
Material Costs $ 517.9 74.6 % $ 669.5 70.3 %
Other Manufacturing Costs 162.5 23.4 % 200.5 21.0 %
Total Cost of Sales $ 680.4 98.0 % $ 870.0 91.3 %
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As summarized above, cost of sales is composed of material costs, a variable
expense, and other manufacturing costs, comprised of both fixed and variable
expenses including direct and indirect labor, outbound freight and overhead
expenses. Material costs were 74.6% of net sales compared to 70.3% in 2007. The
4.3% increase results from increases in raw material commodity and component
costs, primarily steel and aluminum that could not be offset by increases in
selling prices. In addition, our other manufacturing costs increased from 21.0%
of net sales in 2007 to 23.4% in 2008. The 2.4% increase is primarily the result
of the inability to reduce the fixed cost component in proportion to the 29.0%
decrease in new trailer volumes.
Retail and distribution segment cost of sales was $135.9 million in 2008, a
decrease of $4.4 million, or 3.1% compared to 2007. As a percentage of net
sales, cost of sales was 95.7% in 2008 compared to 93.7% in 2007. The increase
in the percentage was primarily the result of a 2.1% increase in raw material
costs as a percentage of net sales due to pricing pressures on used trailers and
reduced sales on higher margin parts and services activities.
Gross Profit
Gross profit in 2008 was $20.9 million, down $70.8 million, or 77.2%, compared
to 2007. Gross profit as a percent of sales was 2.5% in 2008 compared to 8.3% in
2007. Gross profit by segment was as follows (in millions):
Year Ended December 31,
2008 2007 % Change
Gross Profit by Segment:
Manufacturing $ 13.8 $ 82.8 (83.3 )
Retail and Distribution 6.1 9.4 (35.1 )
Intercompany Profit Eliminations 1.0 (0.5 )
Total $ 20.9 $ 91.7 (77.2 )
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Manufacturing segment gross profit was $13.8 million in 2008, a decrease of
$69.0 million, or 83.3%, compared to 2007. Gross profit as a percentage of sales
was 2.0% in 2008 compared to 8.7% in 2007. The decrease in gross profit and
gross profit margin percentage was primarily driven by the 29.0% decline in
volumes and continued increases in raw material costs that outpaced increases in
selling prices.
Retail and distribution segment gross profit was $6.1 million in 2008, a
decrease of $3.3 million, or 35.1%, compared to 2007. Gross profit as a
percentage of sales was 4.3% compared to 6.3% in 2007 due to pricing pressures
on used trailers and reduced parts and service volumes.
General and Administrative Expenses
General and administrative expenses were $44.1 million in 2008, a decrease of
$5.4 million, or 10.9%, compared to the prior year. The decrease was partially
the result of our cost cutting initiatives and efforts to adjust our cost
structure to match the current market demand, which resulted in professional
services expenses being reduced by $4.3 million as a result of litigation
settlements and information technology costs and lowered salaries and employee
related costs resulting from reductions in headcount of $0.4 million, net of
severance costs.
Selling Expenses
Selling expenses were $14.3 million in 2008, a decrease of $1.5 million, or
9.2%, compared to the prior year. The decrease was partially the result of our
cost cutting initiatives and efforts to adjust our cost structure to match the
current market demand resulting in lower salaries and other employee related
costs resulting from reductions in headcount of $0.5 million, net of severance
costs, and reductions in advertising and promotional activities of $0.7 million.
Impairment of Goodwill
We reviewed our goodwill during the fourth quarter of 2008 and, based on a
combination of factors, including the significant decline in our market
capitalization as well as the current decline in the U.S. economy, we concluded
that indicators of potential impairment were present. Under Statement of
Financial Accounting Standards No. 142, Goodwill and Other Intangible Assets,
the measurement of impairment of goodwill consists of a two step process. The
first step requires us to compare the fair value of the reporting unit to its
carrying value. During the fourth quarter, we completed a valuation of the fair
value of our reporting units that incorporated existing market based
considerations as well as discounted cash flows based on current and projected
results. Based on this evaluation, it was determined that the carrying value of
both our platform trailer and wood product manufacturing operations exceeded
fair value. The second step involves determining an implied fair value of each
reporting unit's goodwill as compared to its carrying value. After calculating
the implied fair value of the goodwill by deducting the fair value of all
tangible and intangible net assets of the reporting unit from the fair value of
the reporting unit, it was determined that the recorded goodwill of
$66.3 million was fully impaired. Based on these facts and circumstances, we
recorded a non-cash goodwill impairment of $66.3 million.
Other Income (Expense)
Gain on debt extinguishment in 2008 of $0.2 million represents the gain
recognized on the extinguishment of $104.5 million of our Senior Convertible
Notes, which were purchased at a discount to par value, net of related deferred
debt issuance costs.
Income Taxes
In 2008, we recognized income tax expense of $17.1 million compared to
$8.4 million in 2007. The effective rate for 2008 was (15.7%). This rate differs
from the U.S. federal statutory rate of 35% primarily due to the recognition of
a full valuation allowance against our net deferred tax asset and the write-off
of non-deductible goodwill. As of December 31, 2008, we had $93.1 million of
remaining U.S. federal income tax net operating loss carryforwards, which will
expire in 2022 if unused, and which may be subject to other limitations on use
under I.R.S. rules.
2007 Compared to 2006
Net Sales
Net sales in 2007 were $1.1 billion, a decrease of $209.6 million, or 16.0%,
compared to 2006. By business segment, net external sales and related units sold
were as follows (in millions, except unit data):
Year Ended December 31,
2007 2006 % Change
Sales by Segment:
Manufacturing $ 952.8 $ 1,120.7 (15.0 )
Retail and Distribution 149.7 191.5 (21.8 )
Total $ 1,102.5 $ 1,312.2 (16.0 )
New Trailers: (units)
Manufacturing 43,400 55,500 (21.8 )
Retail and Distribution 3,000 3,900 (23.1 )
Total 46,400 59,400 (21.9 )
Used Trailers 4,400 6,600 (33.3 )
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Manufacturing segment sales for 2007 were $952.8 million, a decrease of
$167.9 million, or 15.0%, compared to 2006. This decrease was primarily due to a
decline in van sales of 11,800 units, or approximately $229.6 million, due to
weak market demand. This decrease was partially offset by higher average selling
prices for vans, which had a positive impact of $67.7 million. Sales price
improvements resulted from the effort to offset material price increases and a
favorable product mix as we shipped a larger number of the higher-priced
refrigerated units and fewer lower-priced FreightPro®, pup trailers and
converter dollies in 2007 compared to 2006. Sales of platform units decreased
$4.0 million compared to 2006 as the impact of owning Transcraft for an
additional two months was more than offset by the decline in volume.
Retail and distribution segment sales were $149.7 million in 2007, a decrease of
$41.7 million, or 21.8%, compared to 2006. New and used trailer sales decreased
$19.7 million and $19.1 million, respectively, compared to 2006 primarily as a
result of the overall decline in the market. Parts and service sales were
$40.6 million in 2007, a decrease of $1.6 million, or 3.8%, compared to 2006 due
to weak customer demand.
Gross Profit
Gross profit in 2007 was $91.7 million compared to $104.5 million in 2006, a
decrease of $12.8 million, or 12.2%. Gross profit as a percent of sales was 8.3%
in 2007 compared to 8.0% in 2006. Gross profit by segment was as follows (in
millions):
Year Ended December 31,
2007 2006 % Change
Gross Profit by Segment:
Manufacturing $ 82.8 $ 89.5 (7.5 )
Retail and Distribution 9.4 15.4 (39.0 )
Intercompany Profit Eliminations (0.5 ) (0.4 )
Total $ 91.7 $ 104.5 (12.2 )
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Manufacturing segment gross profit as a percentage of sales was 8.7% compared to 8.0% in 2006. Gross profit was $82.8 million in 2007, a decrease of $6.7 million, or 7.5%, compared to 2006. The gross profit margin percentage was favorably impacted by increases in the overall average selling prices for new trailers that outpaced increased raw material costs and effective management of operating costs. Offsetting these improvements was the 21.8% decline in new trailer units sold in 2007 compared to 2006. Additionally, we were able to regain operating efficiencies that were adversely impacted in 2006 as a result of implementing a new ERP system. Transcraft's contributions to gross profit increased in 2007 from the prior year period due to Transcraft having an additional two months in the current year. . . .
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