10-K: Annual report pursuant to Section 13 and 15(d)
Published on May 16, 2014
UNITED STATES
SECURITIES AND EXCHANGE COMMISSION
Washington D.C. 20549
Form 10-K
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ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 |
For the fiscal year ended March 31, 2014
Or
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TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 |
For the transition period from to .
Commission file number 001-32312
Novelis Inc.
(Exact name of registrant as specified in its charter)
Canada |
98-0442987 |
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(State or other jurisdiction of
incorporation or organization)
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(I.R.S. Employer
Identification Number)
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3560 Lenox Road, Suite 2000,
Atlanta, GA
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30326 |
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(Address of principal executive offices) |
(Zip Code) |
(404) 760-4000
(Registrant’s telephone number, including area code)
Securities registered pursuant to Section 12(b) of the Act:
None
Securities registered pursuant to Section 12(g) of the Act:
None
Indicate by check mark if the Registrant is a well-known seasoned issuer, as defined in Rule 405 of the Securities Act of 1933.
Yes ¨ No ý
Indicate by check mark if the Registrant is not required to file reports pursuant to Section 13 or Section 15(d) of the Securities Exchange Act of 1934 (the “Exchange Act”). Yes ¨ No ý
Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Exchange Act during the preceding 12 months (or for such shorter period that the Registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days. Yes ý No ¨
Indicate by check mark whether the registrant has submitted electronically and posted on its corporate Web site, if any, every Interactive Data File required to be submitted and posted pursuant to Rule 405 of Regulation S-T during the preceding 12 months (or for such shorter period that the registrant was required to submit and post such files). Yes ý No ¨
Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of Registrant’s knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K. ¨
Indicate by check mark whether the registrant is a large accelerated filer, an accelerated filer, a non-accelerated filer, or a smaller reporting company. See the definitions of “large accelerated filer,” “accelerated filer” and “smaller reporting company” in Rule 12b-2 of the Exchange Act. (Check one):
Large accelerated filer |
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Accelerated filer |
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Non-accelerated filer |
x (Do not check if a smaller reporting company)
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Smaller reporting company |
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Indicate by check mark whether the Registrant is a shell company (as defined in Rule 12b-2 of the Exchange Act). Yes ¨ No ý
As of May 15, 2014, the registrant had 1,000 common shares outstanding. All of the Registrant’s outstanding shares were held indirectly by Hindalco Industries Ltd., the Registrant’s parent company.
DOCUMENTS INCORPORATED BY REFERENCE
None
TABLE OF CONTENTS
SPECIAL NOTE REGARDING FORWARD-LOOKING STATEMENTS AND MARKET DATA |
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PART I |
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PART II |
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PART III |
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PART IV |
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2
SPECIAL NOTE REGARDING FORWARD-LOOKING STATEMENTS AND MARKET DATA
This document contains forward-looking statements that are based on current expectations, estimates, forecasts and projections about the industry in which we operate, and beliefs and assumptions made by our management. Such statements include, in particular, statements about our plans, strategies and prospects under the headings “Item 1. Business,” “Item 1A. Risk Factors” and “Item 7. Management’s Discussion and Analysis of Financial Condition and Results of Operations.” Words such as “expect,” “anticipate,” “intend,” “plan,” “believe,” “seek,” “estimate” and variations of such words and similar expressions are intended to identify such forward-looking statements. Examples of forward-looking statements in this Annual Report on Form 10-K include, but are not limited to, our expectations with respect to the impact of metal price movements on our financial performance; the effectiveness of our hedging programs and controls; and our future borrowing availability. These statements are based on beliefs and assumptions of Novelis’ management, which in turn are based on currently available information. These statements are not guarantees of future performance and involve assumptions and risks and uncertainties that are difficult to predict. Therefore, actual outcomes and results may differ materially from what is expressed, implied or forecasted in such forward-looking statements. We do not intend, and we disclaim any obligation, to update any forward-looking statements, whether as a result of new information, future events or otherwise.
This document also contains information concerning our markets and products generally, which is forward-looking in nature and is based on a variety of assumptions regarding the ways in which these markets and product categories will develop. These assumptions have been derived from information currently available to us and to the third party industry analysts quoted herein. This information includes, but is not limited to, product shipments and share of production. Actual market results may differ from those predicted. We do not know what impact any of these differences may have on our business, our results of operations, financial condition, and cash flow. Factors that could cause actual results or outcomes to differ from the results expressed or implied by forward-looking statements include, among other things:
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relationships with, and financial and operating conditions of, our customers, suppliers and other stakeholders; |
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changes in the prices and availability of aluminum (or premiums associated with aluminum prices) or other materials and raw materials we use; |
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fluctuations in the supply of, and prices for, energy in the areas in which we maintain production facilities; |
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our ability to access financing to fund current operations and for future capital requirements; |
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the level of our indebtedness and our ability to generate cash to service our indebtedness; |
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lowering of our ratings by a credit rating agency; |
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changes in the relative values of various currencies and the effectiveness of our currency hedging activities; |
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union disputes and other employee relations issues; |
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factors affecting our operations, such as litigation (including product liability claims), environmental remediation and clean-up costs, breakdown of equipment and other events; |
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changes in general economic conditions, including deterioration in the global economy; |
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changes in the fair value of derivative instruments or the failure of counterparties to our derivative instruments to honor their agreements; |
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the capacity and effectiveness of our metal hedging activities; |
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impairment of our goodwill, other intangible assets, and long-lived assets; |
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loss of key management and other personnel, or an inability to attract such management and other personnel; |
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risks relating to future acquisitions or divestitures; |
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our inability to successfully implement our growth initiatives; |
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changes in interest rates that have the effect of increasing the amounts we pay under our senior secured credit facilities, other financing agreements and our defined benefit pension plans; |
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risks relating to certain joint ventures and subsidiaries that we do not entirely control; |
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the effect of derivatives legislation on our ability to hedge risks associated with our business; |
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competition from other aluminum rolled products producers as well as from substitute materials such as steel, glass, plastic and composite materials; |
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demand and pricing within the principal markets for our products as well as seasonality in certain of our customers’ industries; |
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economic, regulatory and political factors within the countries in which we operate or sell our products, including changes in duties or tariffs; and |
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changes in government regulations, particularly those affecting taxes and tax rates, health care reform, climate change, environmental, health or safety compliance. |
The above list of factors is not exhaustive. These and other factors are discussed in more detail under “Item 1A. Risk Factors” and “Item 7. Management’s Discussion and Analysis of Financial Condition and Results of Operations.”
In this Annual Report on Form 10-K, unless otherwise specified, the terms “we,” “our,” “us,” “Company,” and “Novelis.” refer to Novelis Inc., a company incorporated in Canada under the Canadian Business Corporations Act and its subsidiaries. References herein to “Hindalco” refer to Hindalco Industries Limited, which acquired Novelis in May 2007. In October 2007, Rio Tinto Group purchased all of the outstanding shares of Alcan Inc. References herein to “RTA” refer to Rio Tinto Alcan Inc.
Exchange Rate Data
We report our financial statements in United States (U.S.) dollars. The following table sets forth exchange rate information expressed in terms of Canadian dollars per U.S. dollar based on exchange data published daily from Citibank as of 16:00 Greenwich Mean Time (GMT) (11:00 A.M. Eastern Standard Time). The rates set forth below may differ from the actual rates used in our accounting processes and in the preparation of our consolidated financial statements.
Period |
At Period End |
Average Rate(A) |
High |
Low |
||||||||
Year Ended March 31, 2010 |
1.0144 |
1.0848 |
1.1881 |
1.0144 |
||||||||
Year Ended March 31, 2011 |
0.9709 |
1.0206 |
1.0663 |
0.9709 |
||||||||
Year Ended March 31, 2012 |
0.9973 |
0.9922 |
1.0433 |
0.9510 |
||||||||
Year Ended March 31, 2013 |
1.0160 |
1.0030 |
1.0334 |
0.9601 |
||||||||
Year Ended March 31, 2014 |
1.1044 |
1.0577 |
1.1127 |
1.0074 |
(A) |
This represents the average of the 16:00 GMT buying rates on the last day of each month during the period. |
All dollar figures herein are in U.S. dollars unless otherwise indicated.
Commonly Referenced Data
As used in this Annual Report, consolidated “aluminum rolled product shipments,” “flat rolled product shipments,” or "shipments" refers to aluminum rolled products shipments to third parties. “Aluminum rolled product shipments," “flat rolled product shipments,” or "shipments" associated with the regions refers to aluminum rolled product shipments to third parties and intersegment shipments to other Novelis regions. Shipment amounts also include tolling shipments. References to “total shipments” include aluminum rolled product shipments as well as certain other non-rolled product shipments, primarily scrap, used beverage cans (UBCs), ingot, billets, and primary remelt. The term “aluminum rolled products” is synonymous with the terms “flat rolled products” and “FRP” commonly used by manufacturers and third party analysts in our industry. All tonnages are stated in metric tonnes. One metric tonne is equivalent to 2,204.6 pounds. One kilotonne (kt) is 1,000 metric tonnes.
A significant amount of our business is conducted under a conversion model, which allows us to pass through increases or decreases in the price of aluminum to our customers. Most of our flat-rolled products have a price structure with two components: (i) a pass-through aluminum price based on the London Metal Exchange (LME) plus local market premiums and (ii) a “conversion premium” to produce the rolled product which reflects, among other factors, the competitive market conditions for that product. The use of the term “conversion premium” in this Annual Report, refers to the conversion costs plus a margin we charge our customers to produce the rolled product which reflects, among other factors, the competitive market conditions for that product, exclusive of the pass through aluminum price.
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PART I
Item 1. Business
Overview
We are the world’s leading aluminum rolled products producer based on shipment volume in fiscal 2014, with flat rolled product shipments during that period of approximately 2,895 kt. We are also the global leader in the recycling of aluminum. We are the only company of our size and scope focused solely on aluminum rolled products markets and capable of local supply of technologically sophisticated aluminum products in all four major industrialized continents: North America, South America, Europe and Asia. We had “Net sales” of approximately $10 billion for the year ended March 31, 2014.
Our History
Organization and Description of Business
Novelis Inc. was formed in Canada on September 21, 2004. On May 15, 2007, the Company was acquired by Hindalco Industries Limited ("Hindalco") through its indirect wholly-owned subsidiaries, AV Metals Inc. and AV Minerals N.V. All of our common shares are directly held by AV Metals Inc. All AV Metals Inc. common shares are directly held by AV Minerals N.V. All AV Minerals N.V. common shares are directly held by Hindalco. Hindalco is based in India and is an integrated producer of aluminum and copper. Hindalco is the flagship company of the Aditya Birla Group, a multi-national conglomerate with operations in 36 countries.
We produce aluminum sheet and light gauge products primarily for use in the beverage can, automotive, specialties (including consumer electronics, architecture, and other transportation) and foil markets. We also have recycling operations in many of our plants to recycle aluminum, such as UBCs. As of March 31, 2014, we had manufacturing operations in nine countries on four continents: North America, South America, Asia and Europe, through 25 operating facilities, including recycling operations in nine of these plants. In addition to aluminum rolled products plants, our South American business includes primary aluminum smelting and power generation facilities.
Our Industry
The aluminum rolled products market represents the global supply of and demand for aluminum sheet, plate and foil produced either from sheet ingot or continuously cast roll-stock in rolling mills operated by independent aluminum rolled products producers and integrated aluminum companies alike.
Aluminum rolled products are semi-finished aluminum products that constitute the raw material for the manufacture of finished goods ranging from automotive structures and body panels to food and beverage cans. There are two major types of manufacturing processes for aluminum rolled products differing mainly in the process used to achieve the initial stage of processing:
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hot mills — which require sheet ingot, a rectangular slab of aluminum, as starter material; and
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continuous casting mills — which can convert molten metal directly into semi-finished sheet.
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Both processes require subsequent rolling, which we call cold rolling, and finishing steps such as annealing, coating, leveling or slitting to achieve the desired thicknesses, width and metal properties. Most customers receive shipments in the form of aluminum coil, a large roll of metal, which can be fed into their fabrication processes.
Industry Sources of Metal
There are two sources of input material: (1) primary aluminum, such as molten metal, re-melt ingot and sheet ingot; and (2) secondary aluminum, such as recyclable material from fabrication processes, which we refer to as recycled process material, used beverage cans, other post-consumer aluminum and post-industrial scrap.
Primary aluminum and sheet ingot can generally be purchased at prices set on the LME, plus a local market premium that varies by geographic region of delivery, alloying material, form (ingot or molten metal) and purity.
Recycled aluminum is an important and growing source of input material. Aluminum is infinitely recyclable and recycling it requires approximately 5% of the energy needed to produce primary aluminum. As a result, in regions where aluminum is widely used, manufacturers and customers are active in setting up collection processes in which UBCs and other recyclable aluminum products are collected for re-melting and reuse. Manufacturers may also enter into agreements with customers who return recycled process material and pay to have it re-melted and rolled into the same product again, known as tolling.
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Recycled aluminum is generally purchased at a discount as compared to the price of primary aluminum. The spread between the prices for recycled aluminum and the price of primary aluminum varies by the LME primary aluminum price, type and quality of the scrap, geographic region, and other market factors.
Industry End-use Markets
Aluminum rolled products companies produce and sell a wide range of aluminum rolled products, which can be grouped into five end-use markets: (1) packaging; (2) transportation; (3) consumer electronics; (4) architectural and (5) industrial and other. Within each end-use market, aluminum rolled products are manufactured with a variety of alloy mixtures; a range of tempers (hardness), gauges (thickness) and widths; and various coatings and finishes. Large customers typically have customized needs resulting in the development of close relationships with their supplying mills and close technical development relationships.
Aluminum, because of its light weight, recyclability and formability, has a wide variety of uses in packaging and other end-use markets. The recyclability of aluminum enables it to be used, collected, melted and returned to the original product form an unlimited number of times, unlike paper and polyethylene terephthalate (PET) plastic, which deteriorate with every iteration of recycling.
Packaging. Aluminum is used in beverage cans and bottles, food cans, screw caps used in the beverage industry and household foil. Beverage cans are the second largest aluminum rolled products application (behind foil), accounting for approximately 23% of total worldwide shipments in the calendar year ended December 31, 2013, according to market data from Commodity Research Unit International Limited (CRU), an independent business analysis and consultancy group. In addition to their recyclability, aluminum beverage cans offer advantages in fabricating efficiency and product shelf life. Fabricators are able to produce and fill beverage cans at very high speeds, and non-porous aluminum cans provide longer shelf life than PET plastic containers. Additionally, the use of aluminum to package beverages such as craft beer is increasing, as aluminum blocks sunlight and therefore extends the shelf life of the product. Aluminum cans are light, stackable and use space efficiently, making them convenient and cost-efficient to ship.
Beverage can sheet is sold in coil form for the production of can bodies, ends and tabs. The material can be ordered as rolled, degreased, pre-lubricated, pre-treated and/or lacquered. Typically, can makers define their own specifications for material to be delivered in terms of alloy, gauge, width and surface finish.
Household foil is another packaging application and it includes home and institutional aluminum foil wrap sold as a branded or generic product. Known in the industry as packaging foil, it is manufactured in thicknesses ranging from 11 microns to 23 microns. Container foil is used to produce semi-rigid containers such as pie plates and take-out food trays and is usually ordered in a range of thicknesses from 60 microns to 200 microns.
Transportation. Aluminum rolled products are used in vehicle structures as well as automotive body panel applications, including hoods, deck lids, fenders and lift gates. These uses typically result from cooperative efforts between aluminum rolled products manufacturers and their customers that yield tailor-made solutions for specific requirements in alloy selection, fabrication procedure, surface quality and joining. There has been recent growth in certain geographic markets in automotive applications due to the lighter weight, better fuel economy and improved emissions performance associated with these applications. We expect increased growth in this end-use market as automotive companies continue to explore opportunities for ways to reduce the weight (lightweighting) of automobiles as a result of environmental regulations concerning emissions and fuel economy.
Heat exchangers, such as radiators and air conditioners, are an important application for aluminum rolled products in the truck and automobile categories of the transportation end-use market. Original equipment manufacturers also use aluminum sheet with specially treated surfaces and other specific properties for interior and exterior applications. Newly developed alloys are being used in transportation tanks and rigid containers that allow for safer and more economical transportation of hazardous and corrosive materials.
Aluminum is also used in aerospace applications, as well as in the construction of ships’ hulls, superstructures and passenger rail cars because of its strength, light weight, formability and corrosion resistance.
Consumer Electronics. Aluminum’s lightweight characteristics, high formability, ability to conduct electricity and dissipate heat and to offer corrosion resistance makes it useful in a wide variety of electronic applications. Uses of aluminum rolled products in electronics include flat screen televisions, personal computers, laptops, mobile devices, and digital music players.
5
Architectural. Construction is the largest application within this end-use market. Aluminum rolled products developed for the construction industry are often decorative and non-flammable, offer insulating properties, are durable and corrosion resistant, and have a high strength-to-weight ratio. Aluminum siding, gutters, and downspouts comprise a significant amount of construction volume. Other applications include doors, windows, awnings, canopies, facades, roofs and ceilings.
Industrial and Other. Industrial applications include heat exchangers, process and electrical machinery, lighting fixtures and insulation. Other uses of aluminum rolled products in consumer durables include microwaves, coffee makers, air conditioners and cooking utensils.
Market Structure and Competition
The aluminum rolled products market is highly competitive and is characterized by economies of scale, significant capital investments required to achieve and maintain technological capabilities and demanding customer qualification standards. We face competition from a number of companies in all of the geographic regions and end-use markets in which we operate. Our primary competitors are as follows:
North America |
Asia |
Alcoa, Inc. (Alcoa) |
Alcoa |
Aleris International, Inc. (Aleris) |
UACJ Corporation |
Tri-Arrows Aluminum Inc. (Tri-Arrows) |
Kobe Steel Ltd. |
Noranda Aluminum |
Nanshan Aluminum |
Constellium |
Chinalco Group |
Wise Metal Group LLC |
Mingtai |
Asia Aluminum and Glass Co., Ltd |
|
Europe |
Henan Zhongfu Industrial Co., Ltd |
Alcoa |
BinZhou WeiQiao Aluminium Science & Technology Co.Ltd
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Aleris |
China Zhongwang Holdings Limited |
Hydro A.S.A. |
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Constellium |
South America |
Alcoa |
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Companhia Brasileira de Alumínio |
The factors influencing competition vary by region and end-use market, but generally we compete on the basis of our value proposition, including price, product quality, the ability to meet customers’ specifications, range of products offered, lead times, technical support and customer service. In some end-use markets, competition is also affected by fabricators’ requirements that suppliers complete a qualification process to supply their plants. This process can be rigorous and may take many months to complete. As a result, obtaining business from these customers can be a lengthy and expensive process. However, the ability to obtain and maintain these qualifications can represent a competitive advantage.
In addition to competition from others within the aluminum rolled products industry, we, as well as the other aluminum rolled products manufacturers, face competition from non-aluminum material producers, as fabricators and end-users have, in the past, demonstrated a willingness to substitute other materials for aluminum. In packaging (primarily beverage and food cans), aluminum rolled products’ primary competitors are glass, PET plastic, and in some regions, steel. In the transportation end-use market, aluminum rolled products compete mainly with steel and composites. Aluminum competes with wood, plastic, cement and steel in building products applications. Factors affecting competition with substitute materials include price, ease of manufacture, consumer preference and performance characteristics.
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Key Factors Affecting Supply and Demand
The following factors have historically affected the supply of aluminum rolled products:
Production Capacity and Alternative Technology. In the aluminum rolled products industry, the addition of rolling capacity requires large capital investments and significant plant construction or expansion, and typically requires long lead-time equipment orders. Advances in technological capabilities allow aluminum rolled products producers to better align product portfolios and supply with industry demand. In addition, there are lower cost ways to enter the industry such as continuous casting, which offers the ability to increase capacity in smaller increments than is possible with hot mill additions. This enables production capacity to better adjust to small year-over-year increases in demand; however the continuous casting process results in the production of a more limited range of products.
Trade. Some trade flows do occur between regions despite shipping costs, import duties and the need for localized customer support. Higher value-added products are more likely to be traded internationally, especially if demand in certain markets exceeds local supply. With respect to less technically demanding applications, emerging markets with low cost inputs may export commodity aluminum rolled products to larger, more mature markets, as we have seen with China. Accordingly, regional changes in supply, such as plant expansions, have some impact on the worldwide supply of aluminum rolled products.
The following factors have historically affected the demand for aluminum rolled products:
Economic Growth. We believe that economic growth is a significant driver of aluminum rolled products demand. In mature markets, growth in demand has typically correlated closely with growth in industrial production.
In many emerging markets such as Brazil, growth in demand typically exceeds industrial production growth largely because of expanding infrastructures, capital investments and rising incomes that often accompany economic growth in these markets.
Substitution Trends. Manufacturers’ willingness to substitute other materials for aluminum in their products and competition from substitution materials suppliers also affect demand. There has been a strong substitution trend toward aluminum in the use of vehicles as automobile manufacturers look for ways to meet fuel efficiency regulations and reduce carbon emissions in a cost-efficient manner. As a result of aluminum’s durability, strength and light weight, automobile manufacturers are substituting aluminum for heavier alternatives such as steel and iron. Consequently, demand for flat rolled aluminum products has increased. We also see strong substitution trends toward aluminum and away from other packaging materials in the beverage can market globally, except for North America which is already a mature market.
Seasonality. During our third fiscal quarter, we typically experience seasonal slowdowns resulting in lower shipment volumes. This is a result of declines in overall production output due primarily to holidays and cooler weather in North America and Europe, our two largest operating regions. We also experience downtime at our mills and customers’ mills due to scheduled plant maintenance and are impacted to a lesser extent by the seasonal downturn in construction activity.
Sustainability. Growing awareness of environmentalism and demand for recyclable products has increased the demand for aluminum rolled products. Unlike other commonly recycled materials such as paper or PET plastic, aluminum can be recycled an unlimited number of times without affecting the quality of the product. Additionally, the recycling process uses 95% less energy than is required to produce primary aluminum from mining and smelting, with an equivalent reduction in greenhouse gas emissions.
Our Business Strategy
Our primary objective is to deliver customer and shareholder value by being the most technologically advanced, innovative and profitable aluminum rolled products company in the world. We intend to achieve this objective through the following areas of focus:
Operate as “One Novelis” — a Fully-integrated Global Company
We intend to continue to build on our focused business model to operate as “One Novelis.” The term “One Novelis” refers to our focus on being a truly integrated, global company driven by a singular focus. An important part of the One Novelis concept is our highly-focused, pass-through business model that utilizes our manufacturing excellence, our risk management expertise, our value-added conversion premium-based pricing, and, more importantly, our growing ability to leverage our global assets according to a single, corporate-wide vision. We believe this integrated approach is the foundation for the effective execution of our strategy across the Novelis system.
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We strive to service our customers in a consistent, global manner through seamless alignment of goals, methods and metrics across the organization to improve communication and by implementation of strategic initiatives. These initiatives have resulted in solid operating margins and performance, and we will continue to take actions to ensure we are aligned to best leverage our operations globally.
Focus on Our Core Premium Products to Drive Enhanced Profitability
We focus on capturing the global growth we see in our premium product markets of beverage can, automotive and specialties. We plan to continue improving our product mix and margins by leveraging our world-class assets and technical capabilities. Our management approach helps us to systematically identify opportunities to improve the profitability of our operations through product portfolio analysis. This ensures that we focus on growing in attractive market segments, while also taking actions to exit unattractive ones. During fiscal year 2013, we sold three foil and packaging plants in Europe and we have executed an agreement to sell certain foil operations in North America to focus on our premium products, such as growth in automotive. Additionally, we are taking steps to exit certain non-core operations in Brazil, including executing an agreement to sell our hydroelectric power operations. We will continue to focus on our core products while investing in growth markets.
Pursue Organic Growth Through Capital Investments in Growth Markets
We have invested to increase our capacity in growth markets. Our international presence positions us well to capture additional growth opportunities in targeted aluminum rolled products. In particular, we believe there is strong automotive growth potential worldwide. Additionally, we believe Asia and South America have high growth potential in areas such as beverage cans and specialties. While our existing manufacturing and operating presence positions us well to capture this growth, we are making incremental capital expenditures in these areas. The following table summarizes our significant global expansion projects, the estimated capacity and estimated or actual commission start date.
Location |
Description of Expansion |
Estimated Capacity (at full capacity) |
Actual or estimated commission start date
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North America |
||||||
Oswego, NY |
Automotive sheet finishing capacity |
240 kt |
July 2013 |
|||
Oswego, NY |
Automotive sheet finishing capacity |
120 kt |
End CY2015 |
|||
Europe |
||||||
Nachterstedt, Germany |
Recycling plant |
400 kt |
Mid CY2014 |
|||
Nachterstedt, Germany |
Automotive sheet finishing expansion |
120 kt |
End CY2015 |
|||
Asia |
||||||
Ulsan & Yeongju, South Korea |
Rolling expansion |
350 kt |
July 2013 |
|||
Yeongju, South Korea |
Recycling expansion |
265 kt |
October 2012 |
|||
Changzhou, China |
Automotive sheet finishing plant |
120 kt |
Mid CY2014 |
|||
South America |
||||||
Pinda, Brazil |
Rolling expansion |
220 kt |
December 2012 |
|||
Pinda, Brazil |
Can coating line |
100 kt |
January 2014 |
|||
Pinda, Brazil |
Recycling expansion |
190 kt |
February 2014 |
Creating a Closed-Loop Business Model for a Sustainable Future
Novelis is in the process of shifting our business model from a traditional linear structure to a closed-loop model. Although creating a true closed loop business model will require working with many stakeholders in our value chain, we are focusing right now on the most material aspects and those where we can have the most impact. To embark upon tackling our biggest issues, we have set 10 goals for 2020, which address recycled inputs, greenhouse gas emissions, energy, water, waste, as well as social targets for health and safety, ethical guidelines, employee performance, and the communities where we operate. We report our progress against these targets annually through our global sustainability report.
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Novelis is working closely with our customers to bring innovation to products in which our aluminum is used. Through lifecycle analysis, aluminum has shown to be a key material for lightweighting automobiles in order to increase fuel-efficiency. We are positioning ourselves to meet dramatically increased global demand for aluminum from our automobile customers by increasing the number of auto finishing lines in our facilities in North America, Europe, and Asia. We are also working closely with our auto customers to redesign auto alloys to be made with more scrap, as well as to close the loop with them by taking back their production scrap and, in the longer term, end-of-life scrap. For our can customers, Novelis introduced the evercanTM, the first-of-its-kind, independently certified, high-recycled content aluminum beverage can sheet.
One of our goals is to reach 80% recycled content in our products by 2020. In the last three years we have invested nearly $500 million to increase our global recycling capacity. The results of these investments are beginning to be realized, as our recycled input has increased from 33% in fiscal 2011 to 46% in fiscal 2014.
Maintaining a competitive cost structure
We are focused on managing our costs by pursuing a standardized focus on our core operations globally. To achieve this objective, we continue working to standardize our manufacturing processes and the associated upstream and downstream production elements where possible while still allowing the flexibility to respond to local market demands. In addition, we have implemented numerous restructuring initiatives, including the shutdown or sale of facilities, staff rationalization and other activities, all of which have led to significant cost savings that will benefit Novelis for years to come. We plan to focus on maintaining a competitive cost structure, even as we invest in expansions, and we intend to continuously evaluate and implement initiatives to improve operational efficiencies across our plants globally.
Our Operating Segments
Due in part to the regional nature of supply and demand of aluminum rolled products and in order to best serve our customers, we manage our activities on the basis of geographical areas and are organized under four operating segments: North America; Europe; Asia and South America. Each segment manufactures aluminum sheet and light gauge products.
The table below shows “Net sales” and total shipments by segment. For additional financial information related to our operating segments, see Note 21 — Segment, Geographical Area, Major Customer and Major Supplier Information to our accompanying audited consolidated financial statements.
Net sales in millions |
Year Ended March 31, |
|||||||||||
Shipments in kilotonnes |
2014 |
2013 |
2012 |
|||||||||
Consolidated |
||||||||||||
Net sales |
$ |
9,767 |
$ |
9,812 |
$ |
11,063 |
||||||
Total shipments |
3,061 |
2,930 |
2,982 |
|||||||||
North America(A) |
||||||||||||
Net sales |
$ |
3,050 |
$ |
3,405 |
$ |
3,967 |
||||||
Total shipments |
994 |
1,012 |
1,079 |
|||||||||
Europe(A) |
||||||||||||
Net sales |
$ |
3,280 |
$ |
3,181 |
$ |
3,840 |
||||||
Total shipments |
977 |
919 |
965 |
|||||||||
Asia(A) |
||||||||||||
Net sales |
$ |
1,876 |
$ |
1,762 |
$ |
1,830 |
||||||
Total shipments |
640 |
562 |
536 |
|||||||||
South America(A) |
||||||||||||
Net sales |
$ |
1,588 |
$ |
1,391 |
$ |
1,278 |
||||||
Total shipments |
534 |
471 |
417 |
(A) |
"Net sales" and "Total shipments" by segment include intersegment sales and the results of our affiliates on a proportionately consolidated basis, which is consistent with the way we manage our business segments. |
9
The following is a description of our operating segments as of March 31, 2014:
North America
Headquartered in Atlanta, Georgia, Novelis North America operates 10 aluminum rolled products facilities, including two fully dedicated recycling facilities and one facility with recycling operations, and manufactures a broad range of aluminum sheet and light gauge products. End-use markets for this segment include beverage and food cans, containers and packaging, automotive and other transportation applications, architectural and other industrial applications. The majority of North America’s volumes are currently directed toward the beverage can sheet market. The beverage can end-use market is technically demanding to supply. There is currently overcapacity in the beverage can market which has resulted in competitive pricing.
We believe we have a competitive advantage in North America due to our low-cost and technologically advanced manufacturing facilities and technical support capability. Recycling is important in the manufacturing process and we have three facilities in North America that re-melt post-consumer aluminum and recycled process material. Most of the recycled material is from UBCs and the material is cast into sheet ingot for North America’s two can sheet production plants (at our Logan plant in Russellville, Kentucky and our Oswego, New York plant).
In response to the lightweighting trend in the automotive industry, we have expanded our Oswego, New York facility by constructing two automotive finishing lines, which we began commissioning in July 2013. In December 2013, we announced plans to add a third finishing line at our Oswego facility. In September 2013, we entered into an agreement to sell most of our North America foil business, which we expect will close in fiscal 2015, subject to regulatory approval. The transaction represents another step in aligning our global growth strategy with the premium markets of beverage cans, automobiles and specialty products. In August 2012, we withdrew from the UBC recycling joint venture with Alcoa Inc., known as Evermore Recycling LLC (Evermore), and established a new organization for the procurement of scrap in North America, which allows us to more seamlessly operate a global recycling network and strategy.
Europe
Headquartered in Zurich, Switzerland, Novelis Europe operates nine operating plants, including one fully dedicated recycling facility and two facilities with recycling operations, and manufactures a broad range of sheet and foil products. End-use markets for this segment include beverage and food can, automotive, architectural and industrial products, foil and technical products and lithographic sheet. Beverage and food can represent the largest end-use market in terms of shipment volume for Europe. Europe has seven aluminum rolled products facilities, one fully dedicated recycling facility, distribution centers in Italy, and sales offices in several European countries. Operations include our 50% joint venture interest in Aluminium Norf GmbH (Alunorf), which is the world’s largest aluminum rolling and remelt facility. Alunorf supplies high quality can stock, foilstock and feeder stock for finishing at our other European operations.
We are building a fully integrated recycling facility at our Nachterstedt, Germany plant, which will be commissioned in the middle of calendar year 2014 and will be the largest aluminum recycling facility in the world. In December 2013, we announced plans to further expand our Europe production of aluminum automotive sheet products by building a second finishing line at our Nachterstedt, Germany facility.
In June 2012, we completed the sale of three European aluminum foil and packaging plants to Eurofoil, a unit of American Industrial Acquisition Corporation (AIAC). The transaction included foil rolling operations in Rugles, France; Dudelange, Luxembourg; and Berlin, Germany. The transaction represented another step in aligning our global growth strategy on the premium markets of beverage cans, automobiles and specialty products. In March 2012, we made a decision to restructure our lithographic sheet operations in our Göttingen, Germany plant, which included the shutdown of one of our lithographic sheet lines.
10
Asia
Headquartered in Seoul, South Korea, Novelis Asia operates three manufacturing facilities, including two facilities with recycling operations, and manufactures a broad range of sheet and light gauge products. End-use markets include beverage and food cans, electronics, architectural, industrial and other products, automotive and foil. The beverage can market represents the largest end-use market in terms of volume. Recycling is an important part of our operations with recycling facilities at both the Ulsan and Yeongju, South Korea plants. We believe that Asia is well-positioned to benefit from further economic development in China as well as other parts of Asia.
In response to the growing demand in the broader Asia region, we expanded our aluminum rolling and recycling operations in South Korea, which include both hot rolling and cold rolling operations. The move is designed to rapidly bring to market high-quality aluminum rolling capacity aligned with the projected needs of a growing customer base. The expansion includes the construction of a state-of-the-art recycling center primarily for UBCs and a casting operation. Additionally, we are constructing an aluminum automotive sheet finishing plant in China. In fiscal 2014, we commissioned our first recycling center in Vietnam, which handles the procurement, cleaning and baling of UBCs.
South America
Headquartered in Sao Paulo, Brazil, Novelis South America operates two rolling plants, including one facility with recycling operations, along with one primary aluminum smelter and hydroelectric power plants, all of which are located in Brazil. Novelis South America manufactures aluminum rolled products, including can stock, industrial sheet and light gauge. The main markets are beverage and food can, specialty, industrial, foil and other packaging and transportation end-use applications. Beverage can represents the largest end-use application in terms of shipment volume. Our operations in South America include a smelter line, which produces primary aluminum billets, and hydroelectric power plants, which we use to fulfill our own power requirements.
In response to the growing demand for our products in South America, we expanded our aluminum rolling operations to increase capacity at our Pindamonhangaba (Pinda) facility. Additionally, we have installed a new coating line for beverage can end stock and expanded our recycling capacity in our Pinda facility.
In April 2014, we announced plans to sell our hydroelectric power plant facilities to a third party, which is subject to regulatory approvals. In December 2013, we sold certain land to a third party and executed an agreement to sell mining rights on the land, subject to regulatory approvals. In August 2013, we sold our bauxite mining rights and certain alumina assets and related liabilities in Brazil to our parent company, Hindalco. In March 2013, we shut down one of our two primary aluminum smelter lines in Brazil. These actions represent steps to align our global growth strategy with the premium markets of beverage cans, automobiles and specialty products and to increase the use of recycled content in our products.
Financial Information About Geographic Areas
Certain financial information about geographic areas is contained in Note 21— Segment, Geographical Area, Major Customer and Major Supplier Information to our accompanying audited consolidated financial statements.
Raw Materials and Suppliers
The raw materials that we use in manufacturing include primary aluminum, recycled aluminum, sheet ingot, alloying elements and grain refiners. Our smelters also use alumina, caustic soda and calcined petroleum coke and resin. These raw materials are generally available from several sources and are not generally subject to supply constraints under normal market conditions. We also consume considerable amounts of energy in the operation of our facilities.
Aluminum
We obtain aluminum from a number of sources, including the following:
Primary Aluminum Sourcing. We purchased or tolled approximately 1,644 kt of primary aluminum in fiscal 2014 in the form of sheet ingot, standard ingot and molten metal, approximately 32% of which we purchased from Rio Tinto Alcan.
11
Aluminum Products Recycling. We operate facilities in several plants to recycle post-consumer aluminum, such as UBCs collected through recycling programs. In addition, we have agreements with several of our large customers where we have a closed-looped system whereby we take recycled processed material from their fabricating activity and re-melt, cast and roll it to re-supply these customers with aluminum sheet. Other sources of recycled material include lithographic plates, and products with longer lifespans, like cars and buildings, which are starting to become high volume sources of recycled material. We purchased or tolled approximately 1,460 kt of recycled material inputs in fiscal 2014 and are making recycling investments in Europe, Korea and South America to increase the amount of recycled material we use as raw materials.
The materials that we recycle are remelted, cast and then used in our operations. The net effect of all recycling activities is that approximately 46% of our total aluminum rolled product shipments in fiscal 2014 were made with recycled material inputs. Our recycled content performance and methodology are detailed in our annual sustainability report, which can be found at www.novelis.com/sustainability. Information in our sustainability report does not constitute part of this Annual Report on Form 10-K.
Energy
We use several sources of energy in the manufacture and delivery of our aluminum rolled products. In fiscal 2014, natural gas and electricity represented approximately 97% of our energy consumption by cost. We also use fuel oil and transport fuel. The majority of energy usage occurs at our casting centers, at our smelter in South America and during the hot rolling of aluminum. Our cold rolling facilities require relatively less energy. We purchase our natural gas on the open market, which subjects us to market pricing fluctuations. We have in the past and may continue to seek to stabilize our future exposure to natural gas prices through the purchase of derivative instruments. Natural gas prices in Europe, Asia and South America have historically been more stable than in the United States.
A portion of our electricity requirements are purchased pursuant to long-term contracts in the local regions in which we operate. A number of our facilities are located in regions with regulated prices, which affords relatively stable costs. We have fixed pricing on some of our energy supply arrangements. When the market price of energy is above the fixed price within the contract, we are subject to the credit risk of the counterparty in terms of fulfilling the contract to its term, including those favorable contracts which were existent at the date of Hindalco's purchase of Novelis and for which an intangible asset was recorded in purchase accounting.
In South America, we own and operate hydroelectric facilities that met all of our electricity requirements for our smelter operations in fiscal 2014. In March 2014, we made a decision sell our hydroelectric power plant facilities. In April 2014, we executed an agreement to sell our hydroelectric power plant facilities to a third party, subject to regulatory approval.
Our Customers
In fiscal 2014, approximately 54% of our total “Net sales” were to our ten largest customers, most of whom we have been supplying for more than 20 years. To address consolidation trends, we focus significant efforts on developing and maintaining close working relationships with our customers and end-users. Our major customers include:
Beverage and Food Cans |
Automotive |
|
Anheuser-Busch LLC |
Audi Worldwide Company |
|
Affiliates of Ball Corporation |
BMW AG |
|
Can-Pack S.A. |
Daimler AG |
|
Various bottlers of the Coca-Cola System |
Ford Motor Company |
|
Crown Cork & Seal Company |
General Motors LLC |
|
Rexam plc |
Hyundai Motor Company |
|
Jaguar Land Rover Limited |
||
Volvo Group |
||
Construction, Industrial and Other |
Electronics |
|
Amcor Limited |
LG International Corporation |
|
Lotte Aluminum Co. Ltd. |
Samsung Electronics Co., Ltd |
|
Pactiv Corporation |
||
Ryerson Inc. |
12
Our single largest end-use market is beverage can sheet. We sell can sheet directly to beverage makers and bottlers as well as to can fabricators that sell the cans they produce to bottlers. In certain cases, we operate under umbrella agreements with beverage makers and bottlers under which they direct their can fabricators to source their requirements for beverage can body, end and tab stock from us.
The table below shows our “Net sales” to Rexam Plc (Rexam), Anheuser-Busch LLC (Anheuser-Busch), and Affiliates of Ball Corporation, our three largest customers, as a percentage of total “Net sales.”
Year Ended March 31, |
|||||||||
2014 |
2013 |
2012 |
|||||||
Rexam |
17 |
% |
15 |
% |
14 |
% |
|||
Anheuser-Busch LLC |
8 |
% |
11 |
% |
10 |
% |
|||
Affiliates of Ball Corporation |
10 |
% |
10 |
% |
10 |
% |
Distribution and Backlog
We have two principal distribution channels for the end-use markets in which we operate: direct sales to our customers and sales to distributors.
Year Ended March 31, |
|||||||||
2014 |
2013 |
2012 |
|||||||
Direct sales as a percentage of total “Net sales” |
94 |
% |
93 |
% |
93 |
% |
|||
Distributor sales as a percentage of total “Net sales” |
6 |
% |
7 |
% |
7 |
% |
Direct Sales
We supply various end-use markets all over the world through a direct sales force that operates from individual plants or sales offices, as well as from regional sales offices in 20 countries. The direct sales channel typically serves very large, sophisticated fabricators and original equipment manufacturers. Longstanding relationships are maintained with leading companies in industries that use aluminum rolled products. Supply contracts for large global customers generally range from one to five years in length and historically there has been a high degree of renewal business with these customers. Given the customized nature of products and in some cases, large order sizes, switching costs are significant, thus adding to the overall consistency of the customer base.
We also use third party agents or traders in some regions to complement our own sales force. These agents provide service to our customers in countries where we do not have local expertise. We tend to use third party agents in Asia more frequently than in other regions.
Distributors
We also sell our products through aluminum distributors, particularly in North America and Europe. Customers of distributors are widely dispersed, and sales through this channel are highly fragmented. Distributors sell mostly commodity or less specialized products into many end-use markets in small quantities, including the construction and industrial markets. We collaborate with our distributors to develop new end-use markets and improve the supply chain and order efficiencies.
Backlog
We believe that order backlog is not a material aspect of our business.
13
Research and Development
The table below summarizes our “Research and development expenses” in our plants and modern research facilities, which include mini-scale production lines equipped with hot mills, can lines and continuous casters (in millions).
Year Ended March 31, |
||||||||||||
2014 |
2013 |
2012 |
||||||||||
Research and development expenses |
$ |
45 |
$ |
46 |
$ |
44 |
We conduct research and development activities at our plants in order to satisfy current and future customer requirements, improve our products and reduce our conversion costs. Our customers work closely with our research and development professionals to improve their production processes and market options. We have approximately 140 employees dedicated to research and development, located in many of our plants and research centers. We opened a global research and development center in Kennesaw, Georgia that became operational in mid calendar year 2012. The center offers state of the art research and development capabilities to help Novelis meet the global long-term demand for aluminum used for the automotive, beverage can and specialty markets. To reach the Company’s sustainability commitments, a key focus is to help increase the amount of recycled metal content across all product lines while meeting performance requirements.
Our Employees
The table below summarizes our approximate number of employees by region.
Employees |
North
America
|
Europe |
Asia |
South
America
|
Total |
||||||||||
March 31, 2014 |
3,150 |
4,550 |
1,890 |
1,820 |
11,410 |
||||||||||
March 31, 2013 |
3,120 |
4,320 |
1,770 |
1,760 |
10,970 |
We consider our employee relations to be satisfactory. Approximately 63% of our employees are represented by labor unions and their employment conditions are governed by collective bargaining agreements. Collective bargaining agreements are negotiated on a site, regional or national level, and are of varying durations. As of March 31, 2014, approximately 1,400 of our employees were covered under collective bargaining agreements that expire within one year.
Intellectual Property
We actively review intellectual property arising from our operations and our research and development activities and, when appropriate, we apply for patents in appropriate jurisdictions, including the United States and Canada. We currently hold patents and patent applications on approximately 180 different items of intellectual property. While these patents and patent applications are important to our business on an aggregate basis, no single patent or patent application is deemed to be material to our business.
We have applied for, or received registrations for, the “Novelis” word trademark and the Novelis logo trademark in approximately 50 countries where we have significant sales or operations. Novelis uses the Aditya Birla logo under license from Aditya Birla Management Corporation Private Limited.
We have also registered the word “Novelis” and several derivations thereof as domain names in numerous top level domains around the world to protect our presence on the world wide web.
14
Environment, Health and Safety
We own and operate numerous manufacturing and other facilities in various countries around the world. Our operations are subject to environmental laws and regulations from various jurisdictions, which govern, among other things, air emissions, wastewater discharges, the handling, storage and disposal of hazardous substances and wastes, the remediation of contaminated sites, post-mining reclamation and restoration of natural resources, and employee health and safety. Future environmental regulations may impose stricter compliance requirements on the industries in which we operate. Additional equipment or process changes at some of our facilities may be needed to meet future requirements. The cost of meeting these requirements may be significant. Failure to comply with such laws and regulations could subject us to administrative, civil or criminal penalties, obligations to pay damages or other costs, and injunctions and other orders, including orders to cease operations.
We are involved in proceedings under the U.S. Comprehensive Environmental Response, Compensation, and Liability Act, also known as CERCLA or Superfund, or analogous state provisions regarding our liability arising from the usage, storage, treatment or disposal of hazardous substances and wastes at a number of sites in the United States, as well as similar proceedings under the laws and regulations of the other jurisdictions in which we have operations, including Brazil and certain countries in the European Union. Many of these jurisdictions have laws that impose joint and several liability, without regard to fault or the legality of the original conduct, for the costs of environmental remediation, natural resource damages, third party claims, and other expenses. In addition, we are, from time to time, subject to environmental reviews and investigations by relevant governmental authorities.
We have established procedures for regularly evaluating environmental loss contingencies, including those arising from environmental reviews and investigations and any other environmental remediation or compliance matters. We believe we have a reasonable basis for evaluating these environmental loss contingencies, and we also believe we have made reasonable estimates for the costs that are reasonably possible for these environmental loss contingencies. Accordingly, we have established liabilities based on our estimates for the currently anticipated costs associated with these environmental matters. Management has determined that the currently anticipated costs associated with these environmental matters will not, individually or in the aggregate, materially impair our operations or materially adversely affect our financial condition.
Available Information
We are subject to the reporting and information requirements of the Securities Exchange Act of 1934, as amended (Exchange Act) and, as a result, we file periodic reports and other information with the Securities and Exchange Commission (SEC). We make these filings available on our website free of charge, the URL of which is http://www.novelis.com, as soon as reasonably practicable after we electronically file such material with, or furnish it to, the SEC. The SEC maintains a website (http://www.sec.gov) that contains our annual, quarterly and current reports and other information we file electronically with the SEC. You can read and copy any materials we file with the SEC at the SEC’s Public Reference Room at 100 F Street, N.E., Washington, D.C. 20549. You may obtain information on the operation of the Public Reference Room by calling the SEC at 1-800-SEC-0330. Information on our website does not constitute part of this Annual Report on Form 10-K.
15
Item 1A. Risk Factors
In addition to the factors discussed elsewhere in this report, you should consider the following factors, which could materially affect our business, financial condition or results of operations in the future. The following factors, among others, could cause our actual results to differ from those projected in any forward looking statements we make.
Certain of our customers are significant to our revenues, and we could be adversely affected by changes in the business or financial condition of these significant customers or by the loss of their business.
Our ten largest customers accounted for approximately 54%, 51% and 51% of our total “Net sales” for the year ended March 31, 2014, 2013 and 2012, respectively, with Rexam Plc, a leading global beverage can maker, and its affiliates representing approximately 17%, 15% and 14% of our total “Net sales” in the respective periods. A significant downturn in the business or financial condition of our significant customers could materially adversely affect our results of operations and cash flows. In addition, if our existing relationships with significant customers materially deteriorate or are terminated in the future, and we are not successful in replacing business lost from such customers, our results of operations and cash flows could be adversely affected. Some of the longer term contracts under which we supply our customers, including under umbrella agreements such as those described under “Business - Our Customers,” are subject to renewal, renegotiation or re-pricing at periodic intervals or upon changes in competitive supply conditions. Our failure to successfully renew, renegotiate or re-price such agreements could result in a reduction or loss in customer purchase volume or revenue, and if we are not successful in replacing business lost from such customers, our results of operations and cash flows could be adversely affected. The markets in which we operate are competitive and customers may seek to consolidate supplier relationships or change suppliers to obtain cost savings and other benefits.
Our results and short term liquidity can be negatively impacted by timing differences between the prices we pay under purchase contracts and metal prices we charge our customers.
Most of our purchase and sales contracts are based on the LME price for high grade aluminum, and there are typically timing differences between the pricing periods for purchases and sales where purchase prices tend to be fixed and paid earlier than sales prices. This creates a price exposure that we call “metal price lag.” The timing difference associated with metal price lag could positively or negatively impact our operating results and short term liquidity position. We use derivative instruments to manage the timing differences associated with metal price lag.
Our operations consume energy and our profitability and cash flows may decline if energy costs were to rise, or if our energy supplies were interrupted.
We consume substantial amounts of energy in our rolling, casting and smelter operations. The factors that affect our energy costs and supply reliability tend to be specific to each of our facilities. A number of factors could materially adversely affect our energy position including:
• |
increases in costs of natural gas; |
• |
increases in costs of supplied electricity or fuel oil related to transportation; |
• |
interruptions in energy supply due to equipment failure or other causes; |
• |
the inability to extend energy supply contracts upon expiration on economical terms; and |
• |
the inability to pass through energy costs in certain sales contracts. |
In addition, global climate change may increase our costs for energy sources, supplies or raw materials. See We may be affected by global climate change or by legal, regulatory or market responses to such change. If energy costs were to rise, or if energy supplies or supply arrangements were disrupted, our profitability and cash flows could decline.
16
A deterioration of our financial position or a downgrade of our ratings by a credit rating agency could increase our borrowing costs and our business relationships could be adversely affected.
A deterioration of our financial position or a downgrade of our ratings for any reason could increase our borrowing costs and have an adverse effect on our business relationships with customers, suppliers and hedging counterparties. From time to time, we enter into various forms of hedging activities against currency, interest rate, energy or metal price fluctuations. Financial strength and credit ratings are important to the availability and pricing of these hedging and trading activities. As a result, a downgrade of our credit ratings or changes to our level of indebtedness may make it more difficult or costly for us to engage in these activities in the future.
Adverse changes in currency exchange rates could negatively affect our financial results or cash flows and the competitiveness of our aluminum rolled products relative to other materials.
Our businesses and operations are exposed to the effects of changes in the exchange rates of the U.S. dollar, the euro, the British pound, the Brazilian real, the Canadian dollar, the Korean won and other currencies. We have implemented a hedging policy that attempts to manage currency exchange rate risks to an acceptable level based on management's judgment of the appropriate trade-off between risk, opportunity and cost; however, this hedging policy may not successfully or completely eliminate the effects of currency exchange rate fluctuations which could have a material adverse effect on our financial results and cash flows.
We prepare our consolidated financial statements in U.S. dollars, but a portion of our earnings and expenditures are denominated in other currencies, primarily the euro, the Korean won and the Brazilian real. Changes in exchange rates will result in increases or decreases in our operating results and may also affect the book value of our assets located outside the U.S.
Most of our facilities are staffed by a unionized workforce, and union disputes and other employee relations issues could materially adversely affect our financial results.
Approximately 63% of our employees are represented by labor unions under a large number of collective bargaining agreements with varying durations and expiration dates. We may not be able to satisfactorily renegotiate our collective bargaining agreements when they expire. In addition, existing collective bargaining agreements may not prevent a strike or work stoppage at our facilities in the future.
We could be adversely affected by disruptions of our operations.
Breakdown of equipment or other events, including catastrophic events such as war or natural disasters, leading to production interruptions at our plants could have a material adverse effect on our financial results and cash flows. Further, because many of our customers are, to varying degrees, dependent on planned deliveries from our plants, those customers that have to reschedule their own production due to our missed deliveries could pursue claims against us and reduce their future business with us. We may incur costs to correct any of these problems, in addition to facing claims from customers. Further, our reputation among actual and potential customers may be harmed, resulting in a loss of business. While we maintain insurance policies covering, among other things, physical damage, business interruptions and product liability, these policies would not cover all of our losses.
Our operations have been and will continue to be exposed to various business and other risks, changes in conditions and events beyond our control in countries where we have operations or sell products.
We are, and will continue to be, subject to financial, political, economic and business risks in connection with our global operations. We have made investments and carry on production activities in various emerging markets, including China, Brazil, Korea and Malaysia, and we market our products in these countries, as well as certain other countries in Asia, the Middle East and emerging markets in South America. While we anticipate higher growth or attractive production opportunities from these emerging markets, they also present a higher degree of risk than more developed markets. In addition to the business risks inherent in developing and servicing new markets, economic conditions may be more volatile, legal and regulatory systems less developed and predictable, and the possibility of various types of adverse governmental action more pronounced. In addition, inflation, fluctuations in currency and interest rates, competitive factors, civil unrest and labor problems could affect our revenues, expenses and results of operations. Our operations could also be adversely affected by acts of war, terrorism or the threat of any of these events as well as government actions such as controls on imports, exports and prices, tariffs, new forms of taxation, or changes in fiscal regimes and increased government regulation in the countries in which we operate or service customers. Unexpected or uncontrollable events or circumstances in any of these markets could have a material adverse effect on our financial results and cash flows.
17
In addition, relations between the Republic of Korea (which we refer to as Korea) and the Democratic People's Republic of Korea (which we refer to as North Korea) have been tense throughout Korea's modern history. There can be no assurance that the level of tension on the Korean peninsula will not escalate in the future. Attacks may occur on Korea, including on areas in which we operate, which could have a material adverse affect on our operations. If military hostilities increase between North Korea and Korea or the United States, the region could become destabilized and our operations could be halted, and any such hostilities could have a material adverse effect on our operations.
Economic conditions could negatively affect our financial condition and results of operations.
Our financial condition and results of operations depend significantly on worldwide economic conditions. Uncertainty about current or future global economic conditions poses a risk as our customers may postpone purchases in response to tighter credit and negative financial news, which could adversely impact demand for our products. In addition, there can be no assurance that actions we may take in response to economic conditions will be sufficient to counter any continuation or any downturn or disruption. A significant global economic downturn or disruption in the financial markets could have a material adverse effect on our financial condition and results of operations.
Our results of operations, cash flows and liquidity could be adversely affected if we were unable to purchase derivative instruments or if counterparties to our derivative instruments fail to honor their agreements.
We use various derivative instruments to manage the risks arising from fluctuations in aluminum prices, exchange rates, energy prices and interest rates. If for any reason we were unable to purchase derivative instruments to manage these risks, our results of operations, cash flows and liquidity could be adversely affected. In addition, we may be exposed to losses in the future if the counterparties to our derivative instruments fail to honor their agreements. In particular, deterioration in the financial condition of our counterparties and any resulting failure to pay amounts owed to us or to perform obligations or services owed to us could have a negative effect on our business and financial condition. Further, if major financial institutions consolidate and are forced to operate under more restrictive capital constraints and regulations, there could be less liquidity in the derivative markets, which could have a negative effect on our ability to hedge and transact with creditworthy counterparties.
Derivatives legislation could have an adverse impact on our ability to hedge risks associated with our business and on the cost of our hedging activities.
We use over-the-counter (OTC) derivative products to hedge our metal commodity risks and our interest rate and currency risks. The Commodity Futures Trading Commission and the SEC recently have finalized certain rules and regulations to increase regulatory oversight of the OTC markets and the entities that participate in those markets. Other regulations implementing the Dodd-Frank Wall Street Reform and Consumer Protection Act (Dodd-Frank Act) remain to be finalized or implemented and it is not possible to predict when this will be accomplished or what impact these regulations will have on our ability to hedge our business risks, or the costs of doing so.
In addition, the European Market Infrastructure Regulation (EMIR), which became effective in 2012, includes regulations related to the trading, reporting and clearing of derivatives. We have entities and counterparties that are located in jurisdictions subject to EMIR. Our efforts to comply with EMIR, and EMIR's effect on the derivatives markets and their participants, creates similar risks and could have similar adverse impacts as those under the Dodd-Frank Act.
If future regulations subject us to additional capital or margin requirements or other restrictions on our trading and commodity positions, they could have an adverse effect on our ability to hedge risks associated with our business and on the cost of our hedging activities. It is also possible that additional similar regulations may be imposed in other jurisdictions where we conduct business and any such regulations could pose risks and have adverse effects on our operations and profitability.
18
Our goodwill, other intangible assets and other long-lived assets could become impaired, which could require us to take non-cash charges against earnings.
We assess, at least annually and potentially more frequently, whether the value of our goodwill has been impaired. We assess the recoverability of finite-lived other intangible assets and other long-lived assets whenever events or changes in circumstances indicate that we may not be able to recover the asset's carrying amount. Any impairment of goodwill, other intangible assets, or long-lived assets as a result of such analysis would result in a non-cash charge against earnings, which charge could materially adversely affect our reported results of operations.
A significant and sustained decline in our future cash flows, a significant adverse change in the economic environment or slower growth rates could result in the need to perform additional impairment analysis in future periods. If we were to conclude that a write-down of goodwill or other intangible assets is necessary, then we would record such additional charges, which could materially adversely affect our results of operations.
As part of our ongoing evaluation of our operations, we may undertake additional restructuring efforts in the future which could in some instances result in significant severance-related costs, environmental remediation expenses and impairment and other restructuring charges.
We recorded “Restructuring and impairment, net” of $75 million and $47 million for the year ended March 31, 2014 and 2013, respectively, and $6 million and $3 million “Gain on assets held for sale” for the year ended March 31, 2014 and 2013, respectively. During these periods, we announced, among others, the following restructuring actions and programs:
• |
the planned sale of our consumer foil products business in North America, including plants in Toronto, Ontario and Vancouver, British Columbia; |
• |
the sale of certain land, alumina assets, and mining rights in Brazil; |
• |
the shutdown of a potline at our Ouro Preto smelter in Brazil; and |
• |
the sale of three of our European foil operations in Rugles, France; Dudelange, Luxembourg; and Berlin, Germany. |
We may take additional restructuring actions in the future. Any additional restructuring efforts could result in significant severance-related costs, environmental remediation expenses, impairment charges, restructuring charges and related costs and expenses, which could adversely affect our profitability and cash flows.
We may not be able to successfully develop and implement new technology initiatives.
We have invested in, and are involved with, a number of technology and process initiatives. Several technical aspects of these initiatives are still unproven, and the eventual commercial outcomes cannot be assessed with any certainty. Even if we are successful with these initiatives, we may not be able to deploy them in a timely fashion. Accordingly, the costs and benefits from our investments in new technologies and the consequent effects on our financial results may vary from present expectations.
Issues arising during the implementation of our enterprise resource planning system could affect our operating results and ability to manage our business effectively.
During fiscal year 2013, we implemented a new enterprise resource planning (ERP) system in two of our North America plants and in our corporate headquarters, which resulted in temporary business interruptions that adversely impacted our North America operating results. In April 2014, we implemented the ERP system in our European headquarters and our new recycling plant in Germany. As we implement new releases of the ERP system in other locations, we may experience temporary business interruptions that could adversely impact our operating results and our ability to report accurate quarterly results in a timely manner and comply with existing covenants in all our debt agreements. There is no assurance that the new ERP system will operate as designed, which could result in an adverse impact on our operating results, cash flows and financial condition.
19
Security breaches and other disruptions to our information technology networks and systems could interfere with our operations, and could compromise the confidentiality of our proprietary information.
We rely upon information technology networks and systems, some of which are managed by third parties, to process, transmit and store electronic information, and to manage or support a variety of business and manufacturing processes and activities. Additionally, we collect and store sensitive data, including intellectual property, proprietary business information, as well as personally identifiable information of our employees, in data centers and on information technology networks. The secure operation of these information technology networks, and the processing and maintenance of this information is important to our business operations and strategy. Despite security measures and business continuity plans, our information technology networks and systems may be vulnerable to damage, disruptions or shutdowns due to attacks by hackers or breaches due to errors or malfeasance by employees, contractors and others who have access to our networks and systems, or other disruptions during the process of upgrading or replacing computer software or hardware, power outages, computer viruses, telecommunication or utility failures or natural disasters or other catastrophic events. The occurrence of any of these events could compromise our networks and the information stored there could be accessed, publicly disclosed, lost or stolen. Any such access, disclosure or other loss of information could result in legal claims or proceedings, liability or regulatory penalties under laws protecting the privacy of personal information, disrupt operations and reduce the competitive advantage we hope to derive from our investment in new or proprietary business initiatives.
Loss of our key management and other personnel, or an inability to attract and retain such management and other personnel, could adversely impact our business.
We employ all of our senior executive officers and other highly-skilled key employees on an at-will basis, and their employment can be terminated by us or them at any time, for any reason and without notice, subject, in certain cases, to severance payment obligations. Competition for qualified employees among companies that rely heavily on engineering and technology is intense, and if our highly skilled key employees leave us, we may be unable to promptly attract and retain qualified replacement personnel, which could result in our inability to improve manufacturing operations, conduct research activities successfully, develop marketable products, execute expansion projects, and compete effectively for our share of the growth in key markets.
Future acquisitions or divestitures may adversely affect our financial results.
As part of our strategy for growth, we may pursue acquisitions, divestitures or strategic alliances, which may not be completed or, if completed, may not be ultimately beneficial to us. There are numerous risks commonly encountered in strategic transactions, including the risk that we may not be able to complete a transaction that has been announced, effectively integrate businesses acquired or generate the cost savings and synergies anticipated. Failure to do so could have a material adverse effect on our financial results.
Capital investments in organic growth initiatives may not produce the returns we anticipate.
A significant element of our strategy is to invest in opportunities to increase the production capacity of our operating facilities through modifications of and investments in existing facilities and equipment and to evaluate other investments in organic growth in our target markets. In particular, over the past several years we have invested substantial resources into projects intended to raise the recycled content of our products, increase our global automotive finishing capacity and grow our portfolio of premium products. These projects involve numerous risks and uncertainties, including the risk that our forecasted demand levels prove to be inaccurate and the risk that aluminum price trends diminish the benefits we anticipate from our recycling investments. If our capital investments do not produce the benefits we anticipate, our financial condition and results of operations could be adversely affected.
We could be required to make unexpected contributions to our defined benefit pension plans as a result of adverse changes in interest rates and the capital markets.
Most of our pension obligations relate to funded defined benefit pension plans for our employees in the U.S., the U.K. and Canada, unfunded pension benefits in Germany and lump sum indemnities payable to our employees in France, Italy, Korea and Malaysia upon retirement or termination. Our pension plan assets consist primarily of funds invested in listed stocks and bonds. Our estimates of liabilities and expenses for pensions and other postretirement benefits incorporate a number of assumptions, including expected long-term rates of return on plan assets and interest rates used to discount future benefits. Our results of operations, liquidity or shareholder's equity in a particular period could be adversely affected by capital market returns that are less than their assumed long-term rate of return or a decline of the rate used to discount future benefits.
20
If the assets of our pension plans do not achieve assumed investment returns for any period, such deficiency could result in one or more charges against our earnings. In addition, changing economic conditions, poor pension investment returns or other factors may require us to make unexpected cash contributions to the pension plans in the future, preventing the use of such cash for other purposes.
We face risks relating to certain joint ventures and subsidiaries that we do not entirely control.
Some of our activities are, and will in the future be, conducted through entities that we do not entirely control or wholly-own. These entities include our Norf, Germany; and Logan, Kentucky joint ventures, as well as our majority-owned Malaysian subsidiary. Our Malaysian subsidiary is a public company whose shares are listed for trading on the Bursa Malaysia. Under the governing documents, agreements or securities laws applicable to or stock exchange listing rules relative to certain of these joint ventures and subsidiaries, our ability to fully control certain operational matters may be limited. Further, in some cases we do not have rights to prevent a joint venture partner from selling its joint venture interests to a third party.
Hindalco and its interests as equity holder may conflict with the interests of the holders of our senior notes in the future.
Novelis is an indirectly wholly-owned subsidiary of Hindalco. As a result, Hindalco may exercise control over our decisions to enter into any corporate transaction or capital restructuring and has the ability to approve or prevent any transaction that requires the approval of our shareholder. Hindalco may have an interest in pursuing acquisitions, divestitures, financings or other transactions that, in its judgment, could enhance its equity investment, even though such transactions might involve risks to holders of our Senior Notes.
Additionally, Hindalco operates in the aluminum industry and may from time to time acquire and hold interests in businesses that compete, directly or indirectly, with us. Hindalco has no obligation to provide us with financing and is able to sell their equity ownership in us at any time.
If we are unable to obtain sufficient quantities of primary aluminum, recycled aluminum, sheet ingot and other raw materials used in the production of our products, our ability to produce and deliver products or to manufacture products using the desired mix of metal inputs could be adversely affected.
The supply risks relating to our metal inputs vary by input type. Our sheet ingot requirements have historically been supplied, in part, by Rio Tinto Alcan pursuant to agreements with us. For the year ended March 31, 2014, we purchased a majority of our third party sheet ingot requirements from Rio Tinto Alcan's primary metal group. If Rio Tinto Alcan or any other significant supplier of sheet ingot is unable to deliver sufficient quantities of this material on a timely basis, our production may be disrupted and our net sales, profitability and cash flows could be materially adversely affected. Although aluminum is traded on the world markets, developing alternative suppliers of sheet ingot could be time consuming and expensive.
Certain of our manufacturing operations rely on UBCs and other types of aluminum scrap for a portion of our base metal inputs. Competition for UBCs and other types of aluminum scrap is significant, and while we believe we will be able to obtain sufficient quantities to meet our production needs, if we are unable to do so, we could be required to purchase more expensive metal inputs which could have an adverse effect on our profitability and cash flows.
Remelt ingot, which is traded on the LME, may become subject to supply risk created by supply and demand anomalies associated with speculative financing transactions. In a period of rapidly rising demand, restrictions on access to metal that is stored in LME warehouses or restrained in financing transactions could create shortages in the spot market which could interfere with supplies to our facilities and limit production.
21
We face significant price and other forms of competition from other aluminum rolled products producers, which could hurt our results of operations and cash flows.
Generally, the markets in which we operate are highly competitive. We compete primarily on the basis of our value proposition, including price, product quality, ability to meet customers' specifications, range of products offered, lead times, technical support and customer service. Some of our competitors may benefit from greater capital resources, more efficient technologies, lower raw material and energy costs and may be able to sustain longer periods of price competition. In particular, we face increased competition from producers in China, which have significantly lower production costs and pricing. This lower pricing could erode the market prices of our products in the Chinese market and elsewhere.
In addition, our competitive position within the global aluminum rolled products industry may be affected by, among other things, consolidation among our competitors, exchange rate fluctuations that may make our products less competitive in relation to the products of companies based in other countries (despite the U.S. dollar-based input cost and the marginal costs of shipping) and economies of scale in purchasing, production and sales, which accrue to the benefit of some of our competitors. For example, the price gap for aluminum between the Shanghai Futures Exchange and the LME may make our products manufactured in Asia based off LME prices less competitive compared to products manufactured by competitors in China based off SHFE prices.
Increased competition could cause a reduction in our shipment volumes and profitability or increase our expenditures, either of which could have a material adverse effect on our financial results and cash flows.
The end-use markets for certain of our products are highly competitive and customers are willing to accept substitutes for our products.
The end-use markets for certain aluminum rolled products are highly competitive. Aluminum competes with other materials, such as steel, plastics, composite materials and glass, among others, for various applications, including in beverage and food cans, electronics and automotive end-use markets. In the past, customers have demonstrated a willingness to substitute other materials for aluminum. For example, changes in consumer preferences in beverage containers have increased the use of PET plastic containers and glass bottles in recent years. These trends may continue. The willingness of customers to accept substitutes for aluminum products could have a material adverse effect on our financial results and cash flows.
We are subject to a broad range of environmental, health and safety laws and regulations, and we may be exposed to substantial environmental, health and safety costs and liabilities.
We are subject to a broad range of environmental, health and safety laws and regulations in the jurisdictions in which we operate. These laws and regulations impose stringent environmental, health and safety protection standards and permitting requirements regarding, among other things, air emissions, wastewater storage, treatment and discharges, the use and handling of hazardous or toxic materials, waste disposal practices, the remediation of environmental contamination, post-mining reclamation and working conditions for our employees. Some environmental laws, such as Superfund and comparable laws in U.S. states and other jurisdictions worldwide, impose joint and several liability for the cost of environmental remediation, natural resource damages, third party claims, and other expenses, without regard to the fault or the legality of the original conduct.
The costs of complying with these laws and regulations, including participation in assessments and remediation of contaminated sites and installation of pollution control facilities, have been, and in the future could be, significant. In addition, these laws and regulations may also result in substantial environmental liabilities associated with divested assets, third party locations and past activities. In certain instances, these costs and liabilities, as well as related action to be taken by us, could be accelerated or increased if we were to close, divest of or change the principal use of certain facilities with respect to which we may have environmental liabilities or remediation obligations. Currently, we are involved in a number of compliance efforts, remediation activities and legal proceedings concerning environmental matters, including certain activities and proceedings arising under Superfund and comparable laws in U.S. states and other jurisdictions worldwide in which we have operations.
22
We have established liabilities for environmental remediation activities where appropriate. However, the cost of addressing environmental matters (including the timing of any charges related thereto) cannot be predicted with certainty, and these liabilities may not ultimately be adequate, especially in light of changing interpretations of laws and regulations by regulators and courts, the discovery of previously unknown environmental conditions, the risk of governmental orders to carry out additional compliance on certain sites not initially included in remediation in progress, our potential liability to remediate sites for which provisions have not been previously established and the adoption of more stringent environmental laws including, for example, the possibility of increased regulation of the use of bisphenol-A, a chemical component commonly used in the coating of aluminum cans. Such future developments could result in increased environmental costs and liabilities, which could have a material adverse effect on our financial condition, results or cash flows. Furthermore, the failure to comply with our obligations under the environmental laws and regulations could subject us to administrative, civil or criminal penalties, obligations to pay damages or other costs, and injunctions or other orders, including orders to cease operations. In addition, the presence of environmental contamination at our properties could adversely affect our ability to sell property, receive full value for a property or use a property as collateral for a loan.
Some of our current and potential operations are located or could be located in or near communities that may regard such operations as having a detrimental effect on their social and economic circumstances. Community objections could have a material adverse impact upon the profitability or, in extreme cases, the viability of an operation.
We use a variety of hazardous materials and chemicals in our rolling processes, as well as in our smelting operations in Brazil and in connection with maintenance work on our manufacturing facilities. Because of the nature of these substances or related residues, we may be liable for certain costs, including, among others, costs for health-related claims or removal or re-treatment of such substances. Certain of our current and former facilities incorporate asbestos-containing materials, a hazardous substance that has been the subject of health-related claims for occupational exposure. In addition, although we have developed environmental, health and safety programs for our employees, including measures to reduce employee exposure to hazardous substances, and conduct regular assessments at our facilities, we are currently, and in the future may be, involved in claims and litigation filed on behalf of persons alleging injury predominantly as a result of occupational exposure to substances or other hazards at our current or former facilities. It is not possible to predict the ultimate outcome of these claims and lawsuits due to the unpredictable nature of personal injury litigation. If these claims and lawsuits, individually or in the aggregate, were finally resolved against us, our results of operations and cash flows could be adversely affected.
We may be exposed to significant legal proceedings or investigations.
From time to time, we are involved in, or the subject of, disputes, proceedings and investigations with respect to a variety of matters, including environmental, health and safety, product liability, employee, tax, personal injury, contractual and other matters as well as other disputes and proceedings that arise in the ordinary course of business. Certain of these matters are discussed in the preceding risk factor. Any claims against us or any investigations involving us, whether meritorious or not, could be costly to defend or comply with and could divert management's attention as well as operational resources. Any such dispute, litigation or investigation, whether currently pending or threatened or in the future, may have a material adverse effect on our financial results and cash flows.
Product liability claims against us could result in significant costs or negatively impact our reputation and could adversely affect our business results and financial condition.
We are sometimes exposed to warranty and product liability claims. There can be no assurance that we will not experience material product liability losses arising from individual suits or class actions alleging product liability defects or related claims in the future and that these will not have a negative impact on us. We generally maintain insurance against many product liability risks, but there can be no assurance that this coverage will be adequate for any liabilities ultimately incurred. In addition, there is no assurance that insurance will continue to be available on terms acceptable to us. A successful claim that exceeds our available insurance coverage could have a material adverse effect on our financial results and cash flows.
23
We may be affected by global climate change or by legal, regulatory, or market responses to such change.
Increased concern over climate change has led to new and proposed legislative and regulatory initiatives, such as cap-and-trade systems and additional limits on emissions of greenhouse gases. New laws enacted could directly and indirectly affect our customers and suppliers (through an increase in the cost of production or their ability to produce satisfactory products) or our business (through an impact on our inventory availability, cost of sales, operations or demand for the products we sell), which could result in an adverse effect on our financial condition, results of operations and cash flows. Compliance with any new or more stringent laws or regulations, or stricter interpretations of existing laws, could require additional expenditures by us, our customers or our suppliers. Also, we rely on natural gas, electricity, fuel oil and transport fuel to operate our facilities. Any increased costs of these energy sources because of new laws could be passed along to us and our customers and suppliers, which could also have a negative impact on our profitability.
Income tax payments may ultimately differ from amounts currently recorded by the Company. Future tax law changes may materially increase the Company's prospective income tax expense.
We are subject to income taxation in many jurisdictions. Judgment is required in determining our worldwide income tax provision and accordingly there are many transactions and computations for which our final income tax determination is uncertain. We are routinely audited by income tax authorities in many tax jurisdictions. Although we believe the recorded tax estimates are reasonable, the ultimate outcome from any audit (or related litigation) could be materially different from amounts reflected in our income tax provisions and accruals. Future settlements of income tax audits may have a material effect on earnings between the period of initial recognition of tax estimates in the financial statements and the point of ultimate tax audit settlement. Additionally, it is possible that future income tax legislation in any jurisdiction to which we are subject may be enacted that could have a material impact on our worldwide income tax provision beginning with the period that such legislation becomes effective.
Our substantial indebtedness could adversely affect our business.
We have a relatively high degree of leverage. As of March 31, 2014, we had $5.2 billion of indebtedness outstanding. Our substantial indebtedness and interest expense could have important consequences to our company and holders of notes, including:
• |
limiting our ability to borrow additional amounts for working capital, capital expenditures or other general corporate purposes; |
• |
increasing our vulnerability to general adverse economic and industry conditions, including volatility in LME aluminum prices; |
• |
limiting our ability to capitalize on business opportunities and to react to competitive pressures and adverse changes in government regulation; and |
• |
limiting our ability or increasing the costs to refinance indebtedness. |
The covenants in our senior secured credit facilities and the indentures governing our Senior Notes impose operating and financial restrictions on us.
Our senior secured credit facilities and the indentures governing our senior notes impose certain operating and financial restrictions on us. These restrictions limit our ability and the ability of our restricted subsidiaries, among other things, to:
• |
incur additional debt and provide additional guarantees; |
• |
pay dividends and make other restricted payments, including certain investments; |
• |
create or permit certain liens; |
• |
make certain asset sales; |
• |
use the proceeds from the sales of assets and subsidiary stock; |
• |
create or permit restrictions on the ability of our restricted subsidiaries to pay dividends or make other distributions to us; |
• |
engage in certain transactions with affiliates; |
• |
enter into sale and leaseback transactions; and |
• |
consolidate, merge or transfer all or substantially all of our assets or the assets of our restricted subsidiaries. |
See Note 11 - Debt for additional discussion.
24
Item 1B. Unresolved Staff Comments
None.
Item 2. Properties
Our global headquarters are located in Atlanta, Georgia. Our global research and technology center is located in Kennesaw, Georgia, which contains state-of-the-art research and development capabilities to help us better partner and innovate with our customers.
The total number of operating facilities within our operating segments as of March 31, 2014 is shown in the table below, including operating facilities that we jointly own and operate with third parties.
Total
Operating
Facilities
|
Facilities
with recycling
operations
|
|||||
North America |
10 |
3 |
||||
Europe |
9 |
3 |
||||
Asia |
3 |
2 |
||||
South America |
3 |
1 |
||||
Total |
25 |
9 |
The following tables provide information, by operating segment, about the plant locations, processes and major end-use markets/applications for the aluminum rolled products, recycling and primary metal facilities we operated during all or part of the year ended March 31, 2014.
North America
Location |
Plant Processes |
Major End-Use Markets |
||
Berea, Kentucky |
Recycling |
Recycled ingot |
||
Burnaby, British Columbia (A) |
Finishing |
Foil containers |
||
Fairmont, West Virginia |
Cold rolling, finishing |
Foil, HVAC material |
||
Greensboro, Georgia |
Recycling |
Recycled ingot |
||
Kingston, Ontario |
Cold rolling, finishing |
Automotive, construction/industrial |
||
Russellville, Kentucky (B) |
Hot rolling, cold rolling, finishing |
Can stock |
||
Oswego, New York |
Sheet ingot casting, hot rolling, cold rolling, recycling, brazing, finishing |
Can stock, automotive,
construction/industrial,
semi-finished coil
|
||
Terre Haute, Indiana |
Cold rolling, finishing |
Foil |
||
Toronto, Ontario (A) |
Finishing |
Foil, foil containers |
||
Warren, Ohio |
Coating |
Can end stock |
(A) |
In September 2013, we executed an agreement to sell these foil facilities to a third party. The transaction is expected to close sometime in fiscal 2015, subject to regulatory approval. The facilities remain in operation and are classified as held for sale as of March 31, 2014. |
(B) |
We own 40% of the outstanding common shares of Logan Aluminum Inc. (Logan), but we have made equipment investments such that our portion of Logan’s total machine hours has provided us approximately 55% of Logan’s total production. |
Our Oswego, New York facility operates modern equipment used for recycling beverage cans and other aluminum scrap, ingot casting, hot rolling, cold rolling and finishing. The Oswego facility produces can stock, automotive sheet stock, as well as building and industrial products. The facility also provides feedstock to our Kingston, Ontario facility, which produces heat-treated automotive sheet and products for construction and industrial applications, and to our Terre Haute, Indiana and Fairmont, West Virginia facilities, which produce foil and light-gauge sheet.
25
Our Russellville, Kentucky facility (Logan Aluminum Inc., referred to herein as "Logan") is a processing joint venture between us and Tri-Arrows Aluminum Inc. (Tri-Arrows). Logan is a dedicated manufacturer of aluminum sheet products for the can stock market and operates modern and high-speed equipment for ingot casting, hot-rolling, cold-rolling and finishing. A portion of the can end stock is coated at North America’s Warren, Ohio facility, in addition to Logan’s on-site coating assets. Together with Tri-Arrows, we operate Logan as a production cooperative, with each party supplying its own primary metal inputs for conversion at the facility. The converted product is then returned to the supplying party at cost. Logan does not own any of the primary metal inputs or any of the converted products. Most of the fixed assets at Logan are directly owned by us and Tri-Arrows in varying ownership percentages or solely by each party.
We share control of the management of Logan with Tri-Arrows through a board of directors with seven voting members of which we appoint four members and Tri-Arrows appoints three members. Management of Logan is led jointly by two executive officers who are subject to approval by at least five members of the board of directors.
Our Burnaby, British Columbia and Toronto, Ontario facilities spool and package household foil products and report to our foil business unit based in Toronto, Ontario.
Along with our recycling center in Oswego, New York, we own two other fully dedicated recycling facilities in North America, located in Berea, Kentucky and Greensboro, Georgia. Each offers a modern, cost-efficient process to recycle UBCs and other aluminum scrap into sheet ingot to supply our hot mills in Logan and Oswego.
Europe
Location |
Plant Processes |
Major End-Use Markets |
||
Bresso, Italy |
Finishing, painting |
Painted sheet, architectural |
||
Göttingen, Germany |
Cold rolling, finishing, painting |
Can end, can tab, food can, lithographic, painted sheet, automotive |
||
Latchford, United Kingdom |
Recycling |
Sheet ingot from recycled metal |
||
Ludenscheid, Germany |
Foil rolling, finishing, converting |
Foil, packaging |
||
Nachterstedt, Germany |
Cold rolling, finishing, painting |
Automotive, can end, industrial, painted sheet, architectural |
||
Neuss, Germany (A) |
Hot rolling, cold rolling, recycling |
Can stock, foilstock, feeder
stock for finishing operations
|
||
Ohle, Germany |
Cold rolling, finishing, converting |
Foil, packaging |
||
Pieve, Italy |
Continuous casting, cold rolling, finishing, recycling |
Coil for Bresso, industrial |
||
Sierre, Switzerland |
Sheet ingot casting, hot rolling, cold rolling, finishing |
Automotive, industrial |
(A) |
Operated as a 50/50 joint venture between us and Hydro Aluminium Deutschland GmbH (Hydro). |
Aluminium Norf GmbH (Alunorf) in Germany, a 50/50 production-sharing joint venture between us and Hydro, is a large scale, modern manufacturing hub, located in Neuss, Germany, for several of our operations in Europe, and is the largest aluminum rolling mill and remelting operation in the world. Norf supplies hot coil for further processing through cold rolling to some of our other plants, including Göttingen and Nachterstedt in Germany and provides foilstock to our plants in Ohle and Ludenscheid in Germany. Together with Hydro, we operate Alunorf as a production cooperative, with each party supplying its own primary metal inputs for transformation at the facility. The transformed product is then transferred back to the supplying party on a pre-determined cost-plus basis. We own 50% of the equity interest in Norf and Hydro owns the other 50%. We share control of the management of Alunorf with Hydro through a jointly-controlled shareholders’ committee. Management of Alunorf is led jointly by two managing executives, one nominated by us and one nominated by Hydro.
Our Göttingen plant has a paint line as well as lines for can end, food sheet, and automotive. Our Nachterstedt plant cold rolls and finishes mainly automotive sheet and can end stock. We are in the process of expanding our Nachterstedt plant by adding a second automotive sheet finishing line. The Pieve plant, located near Milan, Italy, mainly produces continuous cast coil that is cold rolled into paintstock and sent to the Bresso, Italy plant for painting and some specialty finishing.
26
The Sierre hot rolling plant in Switzerland along with the Nachterstedt and Göttingen plants in Germany are Europe’s leading producers of automotive sheet in terms of shipments. By contract, Novelis must purchase a specified minimum quantity of sheet ingot from Constellium for the Sierre operations. Additionally, we must reserve a significant portion of the total production capacity of the Sierre hot mill to produce aluminum plate for Constellium. These obligations expire on December 31, 2014.
We also have certain converting operations for our automotive products in Wednesbury, U.K.
We are investing in our Nachterstedt, Germany site to build a fully integrated recycling facility, which will be the largest aluminum recycling facility in the world and have the ability to recycle a wide variety of types of scrap.
Asia
Location |
Plant Processes |
Major End-Use Markets |
||
Bukit Raja, Malaysia(A) |
Continuous casting, cold rolling, coating |
Construction/industrial, heavy and light gauge foils |
||
Ulsan, South Korea |
Sheet ingot casting, hot rolling, cold rolling, recycling, finishing |
Can stock, construction/industrial, electronics, foilstock, and recycled material |
||
Yeongju, South Korea |
Sheet ingot casting, hot rolling, cold rolling, recycling, finishing |
Can stock, construction/industrial, electronics, foilstock and recycled material |
(A) |
Ownership of the Bukit Raja plant corresponds to our 59% equity interest in Aluminium Company of Malaysia Berhad, a publicly traded company that operates in Bukit Raja, Selangor, Malaysia. |
Novelis Asia operates recycling furnaces at both its Ulsan and Yeongju facilities in South Korea for the conversion of customer and third-party recycled aluminum. In response to the growing demand for our products, we commissioned additional rolling and recycling operations in South Korea in fiscal 2014. We are also constructing an aluminum automotive sheet finishing plant in China. In fiscal 2014, we commissioned our first recycling center in Vietnam, which handles the procurement, cleaning and baling of UBCs.
South America
Location |
Plant Processes |
Major End-Use Markets |
||
Pindamonhangaba, Brazil |
Sheet ingot casting, hot rolling, cold rolling, recycling, finishing |
Can stock, construction/industrial, foilstock, recycled ingot |
||
Santo Andre, Brazil |
Foil rolling, finishing |
Foil |
||
Ouro Preto, Brazil |
Smelting, sheet ingot and billet casting |
Primary aluminum (extrusion billets) |
Our Pinda rolling and recycling facility in Brazil has an integrated process that includes recycling, sheet ingot casting, hot mill and cold mill operations. A leased coating line produces painted products, including can end stock. Pinda supplies foilstock to our Santo Andre foil plant, which produces converter, household and container foil, among others.
Pinda is the largest aluminum rolling and recycling facility in South America in terms of shipments and the only facility in South America capable of producing can body and end stock. Pinda recycles primarily UBCs, and is engaged in tolling recycled metal for our customers. In response to the growing demand for our products in South America, we have expanded our aluminum rolling operations in Pinda in fiscal 2014. Additionally, we have installed a new coating line for beverage can end stock and expanded the recycling capacity in our Pinda facility at the end of fiscal 2014.
We operate primary aluminum smelting operations and casting at our Ouro Preto, Brazil facility and hydroelectric power generation operations in the state of Minas Gerais. Our owned power generation supplied all of our smelter needs in fiscal 2014. Our hydroelectric power generation operations are classified as held for sale as of March 31, 2014. We also own certain mining rights that are not currently being explored and are classified as held for sale as of March 31, 2014.
27
Item 3. Legal Proceedings
We are a party to litigation incidental to our business from time to time. For additional information regarding litigation to which we are a party, see Note 20 — Commitments and Contingencies to our accompanying audited consolidated financial statements, which are incorporated by reference into this item.
Item 4. Mine Safety Disclosures
Not applicable.
28
PART II
Item 5. Market for Registrant’s Common Equity, Related Shareholder Matters and Issuer Purchases of Equity Securities
There is no established public trading market for the Company’s common stock. Hindalco owns all of the Company’s common stock through indirect wholly-owned subsidiaries, AV Metals Inc. and AV Minerals N.V. None of the equity securities of the Company are authorized for issuance under any equity compensation plan.
Dividends or a return of capital are at the discretion of the board of directors and will depend on, among other things, our financial resources, cash flows generated by our business, our cash requirements, restrictions under and covenant compliance under the instruments governing our indebtedness, being in compliance with the appropriate indentures and covenants under the instruments that govern our indebtedness that would allow us to legally pay dividends or return capital and other relevant factors.
In March 2014, we declared a return of capital to our shareholder, AV Metals Inc., in the amount of $250 million, which we subsequently paid on April 30, 2014.
Item 6. Selected Financial Data
The selected consolidated financial data should be read in conjunction with our consolidated financial statements for the respective periods and the related notes included elsewhere in this Form 10-K.
All of our common shares were indirectly held by Hindalco; thus, earnings per share data are not reported. Amounts in the table below are in millions.
Year Ended
March 31,
|
||||||||||||||||||||
2014 |
2013 |
2012 |
2011 |
2010 |
||||||||||||||||
Net sales |
$ |
9,767 |
$ |
9,812 |
$ |
11,063 |
$ |
10,577 |
$ |
8,673 |
||||||||||
Net income attributable to our common shareholder |
$ |
104 |
$ |
202 |
$ |
63 |
$ |
116 |
$ |
405 |
||||||||||
Return of capital (A) |
$ |
250 |
$ |
— |
$ |
— |
$ |
1,700 |
$ |
— |
March 31, |
||||||||||||||||||||
2014 |
2013 |
2012 |
2011 |
2010 |
||||||||||||||||
Total assets |
$ |
9,114 |
$ |
8,522 |
$ |
8,021 |
$ |
8,296 |
$ |
7,762 |
||||||||||
Long-term debt (including current portion) |
$ |
4,451 |
$ |
4,464 |
$ |
4,344 |
$ |
4,086 |
$ |
2,596 |
||||||||||
Short-term borrowings |
$ |
723 |
$ |
468 |
$ |
18 |
$ |
17 |
$ |
75 |
||||||||||
Cash and cash equivalents |
$ |
509 |
$ |
301 |
$ |
317 |
$ |
311 |
$ |
437 |
||||||||||
Total equity |
$ |
268 |
$ |
239 |
$ |
123 |
$ |
445 |
$ |
1,869 |
(A) |
In December 2010, we declared and paid $1.7 billion to our shareholder as a return of capital. In March 2014, we declared a return of capital to our shareholder, AV Metals Inc., in the amount of $250 million, which we subsequently paid on April 30, 2014. |
29
Item 7. Management’s Discussion and Analysis of Financial Condition and Results of Operations
OVERVIEW AND REFERENCES
Novelis is the world's leading aluminum rolled products producer based on shipment volume in fiscal 2014. We produce aluminum sheet and light gauge products for use in the packaging market, which includes beverage and food can and foil products, as well as for use in the transportation, electronics, architectural and industrial product markets. We are also the world's largest recycler of aluminum and have recycling operations in many of our plants to recycle both post-consumer aluminum and post-industrial aluminum. As of March 31, 2014, we had manufacturing operations in nine countries on four continents, which include 25 operating plants, and recycling operations in nine of these plants. In addition to aluminum rolled products plants, our South American businesses include primary aluminum smelting and power generation facilities. We are the only company of our size and scope focused solely on the aluminum rolled products markets and capable of local supply of technologically sophisticated products in all of our geographic regions, but with the global footprint to service global customers.
The following discussion contains forward-looking statements that reflect our plans, estimates and beliefs. Our actual results could differ materially from those discussed in these forward-looking statements. Factors that could cause or contribute to these differences include, but are not limited to, those discussed below and elsewhere in this Annual Report, particularly in “Special Note Regarding Forward-Looking Statements and Market Data” and “Risk Factors.”
30
HIGHLIGHTS
Demand for our automotive products continues to grow rapidly resulting in higher automotive shipments in Europe and North America compared to prior year. We continue to make significant investments in our automotive sheet finishing operations as the automotive industry is using more aluminum in vehicles to improve fuel efficiency by reducing the vehicle weight. In July 2013, we began the commissioning phase of two automotive sheet finishing lines at our Oswego, New York facility, which will result in approximately 240 kt of additional automotive finishing capacity annually when operating at full capacity. The construction of our new automotive sheet finishing plant in Changzhou, China is progressing well and we expect to begin the commissioning phase in the middle of calendar year 2014, which will result in approximately 120 kt of additional finishing capacity when operating at full capacity. In December 2013, we announced plans to invest an additional $205 million to further expand our global production of aluminum automotive sheet products by building a third finishing line at our Oswego, New York facility and a second finishing line at our Nachterstedt, Germany facility. These projects are expected to begin commissioning in late calendar year 2015 and each will add approximately 120 kt of capacity. With these latest expansions, the Company’s global automotive sheet capacity will increase to approximately 900 kt per year when operating at full capacity.
Shipments of our flat rolled products increased from 2,786 kt in fiscal 2013 to 2,895 kt in fiscal 2014. Our recent rolling expansion in our Pindamonhangaba (Pinda) facility, coupled with strong demand in Brazil, contributed to the higher shipments and strong operating results in South America. Shipments were also up in Europe in fiscal 2014 compared to fiscal 2013, driven by higher automotive and can product shipments. Our recent rolling expansion in South Korea contributed to the higher shipment levels in our Asia region. Shipments in North America were down compared to prior year driven by lower can product shipments.
We increased the amount of recycled content in our products over this past fiscal year from 43% to 46%. Our recent recycling facility expansion in Yeongju, South Korea was a significant driver of higher recycled content, which is a component of our strategy to achieve 80% recycled content in our products by 2020. Our recycling expansion in Nachterstedt, Germany will be commissioned in the middle of calendar year 2014 and will become the largest aluminum recycling facility in the world. We began the commissioning process of our recycling expansion at our Pinda facility in Brazil in February 2014. Additionally, we are expanding our recycling operations in Oswego, New York to support the increase in automotive scrap. In April 2014, we announced that Red Hare Brewing Company will launch the world's first commercial use of evercanTM, the Company's high-recycled content aluminum sheet for beverage cans. Cans made of the evercanTM aluminum sheet, which are made of a guaranteed minimum 90% recycled content, are expected to be on store shelves beginning in May 2014.
The competitive landscape in which we operate has put downward pressure on conversion premiums in North America, Europe, and Asia, primarily in can and specialty products. In North America, overcapacity in the beverage can market has resulted in lower conversion premiums and a decline in can shipments in the region. In Europe, we have experienced a reduction in can prices with the renewal of certain customer contracts. In Asia, we are facing more competition, primarily from FRP suppliers in China, which has resulted in lower conversion premiums. Additionally, the higher local market premium on aluminum has increased our cost of metal. Many of our competitors in the region base their metal purchases off the Shanghai Metal Exchange, which does not have a local market premium and puts us at a disadvantage competitively.
We reported "Net income" of $104 million in the year ended March 31, 2014, which is down compared to $203 million in the year ended March 31, 2013. Cash flow provided by operating activities was $702 million for the year ended March 31, 2014 compared to $203 million in the prior year.
All of our strategic expansion projects are progressing well. We spent $717 million on capital expenditures globally for the year ended March 31, 2014, primarily on our global strategic expansion projects.
31
BUSINESS AND INDUSTRY CLIMATE
Current regulations, including the Corporate Average Fuel Economy (CAFE) standards in the U.S., require significant reductions in fuel consumption by vehicles. The demand for aluminum by the automotive industry continues to grow rapidly, driven by these regulations and the need to lightweight vehicles to improve fuel efficiency. We are estimating the automotive aluminum market to grow significantly through the end of the decade, which is driving the significant investments we are making to our automotive sheet finishing in North America, Europe, and Asia. Consumer demand for carbonated soft drinks in North America has declined, creating excess capacity in the can market in the region. We expect the overcapacity for can products in North America to eventually tighten as producers of flat rolled aluminum products shift more hot mill rolling capacity towards automotive products. The aluminum can market is growing in our other regions due to a combination of substitution trends and growing economic development. The competitive landscape in which we operate continues to put downward pressure on conversion premiums in North America, Europe, and Asia, primarily in can and specialty products.
The primary and sheet ingot aluminum market continues to be impacted by excess capacity globally, as reflected in lower LME average aluminum prices we pay and pass through to our customers as a component of net sales. The lower average prices reduced the overall benefit we realized from the utilization of recycled metal. Our overall benefit was also reduced by a decline in the discounts off LME aluminum prices we pay on the procurement of recycled metal. We were able to offset a portion of these declines by increasing the use of recycled metal driven primarily by our additional recycling capacity in our Yeongju, South Korea facility. The prices we pay for aluminum also include local market premiums, which we pass through to most of our customers. The local market premiums globally have historically been fairly stable but have been more volatile recently. Local market premiums have increased significantly over the past couple years, offsetting some of the decrease in average LME aluminum prices.
Key Sales and Shipment Trends
(in millions, except shipments which are in kt) | ||||||||||||||||||||||||||||||||||||||||
Three Months Ended |
Year Ended |
Three Months Ended (A) |
Year Ended |
|||||||||||||||||||||||||||||||||||||
Jun 30, 2012 |
Sept 30, 2012 |
Dec 31, 2012 |
Mar 31, 2013 |
Mar 31, 2013 |
Jun 30, 2013 |
Sept 30, 2013 |
Dec 31, 2013 |
Mar 31, 2014 |
Mar 31, 2014 |
|||||||||||||||||||||||||||||||
Net sales |
$ |
2,550 |
$ |
2,441 |
$ |
2,321 |
$ |
2,500 |
$ |
9,812 |
$ |
2,401 |
$ |
2,414 |
$ |
2,403 |
$ |
2,549 |
$ |
9,767 |
||||||||||||||||||||
Percentage increase (decrease) in net sales versus comparable previous year period |
(18 |
)% |
(15 |
)% |
(6 |
)% |
(4 |
)% |
(11 |
)% |
(6 |
)% |
(1 |
)% |
4 |
% |
2 |
% |
— |
% |
||||||||||||||||||||
Rolled product shipments: | ||||||||||||||||||||||||||||||||||||||||
North America |
266 |
269 |
216 |
239 |
990 |
238 |
238 |
235 |
247 |
958 |
||||||||||||||||||||||||||||||
Europe |
233 |
218 |
192 |
218 |
861 |
232 |
225 |
212 |
242 |
911 |
||||||||||||||||||||||||||||||
Asia |
136 |
142 |
141 |
143 |
562 |
162 |
156 |
165 |
157 |
640 |
||||||||||||||||||||||||||||||
South America |
89 |
92 |
107 |
107 |
395 |
92 |
108 |
123 |
124 |
447 |
||||||||||||||||||||||||||||||
Eliminations |
(2 |
) |
(2 |
) |
(9 |
) |
(9 |
) |
(22 |
) |
(16 |
) |
(14 |
) |
(14 |
) |
(17 |
) |
(61 |
) |
||||||||||||||||||||
Total |
722 |
719 |
647 |
698 |
2,786 |
708 |
713 |
721 |
753 |
2,895 |
||||||||||||||||||||||||||||||
The following summarizes the percentage increase (decrease) in rolled product shipments versus the comparable previous year period: | ||||||||||||||||||||||||||||||||||||||||
North America |
(8 |
)% |
(2 |
)% |
(13 |
)% |
(6 |
)% |
(7 |
)% |
(11 |
)% |
(12 |
)% |
9 |
% |
3 |
% |
(3 |
)% |
||||||||||||||||||||
Europe |
(2 |
)% |
(4 |
)% |
5 |
% |
(5 |
)% |
(2 |
)% |
— |
% |
3 |
% |
10 |
% |
11 |
% |
6 |
% |
||||||||||||||||||||
Asia |
(11 |
)% |
8 |
% |
21 |
% |
15 |
% |
7 |
% |
19 |
% |
10 |
% |
17 |
% |
10 |
% |
14 |
% |
||||||||||||||||||||
South America |
(1 |
)% |
5 |
% |
7 |
% |
10 |
% |
5 |
% |
3 |
% |
17 |
% |
15 |
% |
16 |
% |
13 |
% |
||||||||||||||||||||
Total |
(6 |
)% |
— |
% |
— |
% |
(1 |
)% |
(2 |
)% |
(2 |
)% |
(1 |
)% |
11 |
% |
8 |
% |
4 |
% |
(A) |
These periods reflect adjustments that reduce "Net sales" in the three months ended June 30, September 30, and December 31, 2013 by $7 million, $13 million, and $19 million, respectively, due to a change from gross to net classification for certain sales transactions in Europe.
|
32
Business Model and Key Concepts
Conversion Business Model
A significant amount of our business is conducted under a conversion model, which allows us to pass through increases or decreases in the price of aluminum to our customers. Nearly all of our flat-rolled products have a price structure with two components: (i) a pass-through aluminum price based on the LME plus local market premiums and (ii) a “conversion premium” to produce the rolled product which reflects, among other factors, the competitive market conditions for that product.
Metal Price Lag and Related Hedging Activities
Increases or decreases in the average price of aluminum directly impact “Net sales,” “Cost of goods sold (exclusive of depreciation and amortization)” and working capital. The timing of these impacts varies based on contractual arrangements with customers and metal suppliers in each region. These timing impacts are referred to as metal price lag. Metal price lag exists due to: 1) the period of time between the pricing of our purchases of metal, holding and processing the metal, and the pricing of the sale of finished inventory to our customers, and 2) certain customer contracts containing fixed forward price commitments which result in exposure to changes in metal prices for the period of time between when our sales price fixes and the sale actually occurs.
We use LME aluminum forward contracts to preserve our conversion margins and manage the timing differences associated with metal price lag. These derivatives directly hedge the economic risk of future metal price fluctuations to ensure we sell metal for the same price at which we purchase metal.
See Segment Review below for the impact of metal price lag on each of our segments.
LME Aluminum Prices
The average (based on the simple average of the monthly averages) and closing prices based upon the LME prices for aluminum for the years ended March 31, 2014, 2013, and 2012 are as follows:
Percent Change |
||||||||||||||||||
Year Ended March 31, |
Year Ended
March 31, 2013
versus
|
Year Ended
March 31, 2012
versus
|
||||||||||||||||
2014 |
2013 |
2012 |
March 31, 2014 |
March 31, 2013 |
||||||||||||||
London Metal Exchange Prices |
||||||||||||||||||
Aluminum (per metric tonne, and presented in U.S. dollars): | ||||||||||||||||||
Closing cash price as of beginning of period |
$ |
1,882 |
$ |
2,099 |
$ |
2,600 |
(10 |
)% |
(19 |
)% |
||||||||
Average cash price during period |
$ |
1,773 |
$ |
1,976 |
$ |
2,318 |
(10 |
)% |
(15 |
)% |
||||||||
Closing cash price as of end of period |
$ |
1,731 |
$ |
1,882 |
$ |
2,099 |
(8 |
)% |
(10 |
)% |
We elect to apply hedge accounting to better match the recognition of gains or losses on certain derivative instruments with the recognition of the underlying exposure being hedged in the statement of operations. For undesignated metal derivatives, there are timing differences between the recognition of unrealized gains or losses on the derivatives and the recognition of the underlying exposure in the statement of operations. The recognition of unrealized gains and losses on undesignated metal derivative positions typically precedes inventory cost recognition, customer delivery, revenue recognition, and the realized gains or losses on the derivatives. The timing difference between the recognition of unrealized gains and losses on undesignated metal derivatives and cost or revenue recognition impacts “Income before income taxes” and “Net income.” Gains and losses on metal derivative contracts are not recognized in “Segment income” until realized.
Average aluminum prices were lower by 10% in fiscal 2014 compared to fiscal 2013, and lower by 15% in fiscal 2013 compared to fiscal 2012. The fluctuating prices and timing of when derivatives are realized resulted in $9 million net unrealized losses on undesignated metal derivatives in fiscal 2014, $8 million of net gains in fiscal 2013, and $25 million of net losses in fiscal 2012. The reduction in volatility in our unrealized gains and losses compared to fiscal years prior to 2013 is attributable to the Company's application of hedge accounting for our derivative transactions.
33
Recycled aluminum is generally purchased at a discount as compared to the price of primary aluminum. The benefit we receive from utilizing recycled metal is influenced by the spread between the prices for recycled aluminum and the LME primary aluminum price. Average LME aluminum prices were $203 per metric tonne lower in fiscal 2014 compared to fiscal 2013, which had an unfavorable impact on the benefits we realize from utilizing recycled metal. Additionally, the spread between the prices we pay for the recycled aluminum and LME primary aluminum prices tightened in fiscal 2014 compared to fiscal 2013, which lowered the benefits we realized from utilizing recycled metal.
Foreign Currency and Related Hedging Activities
We operate a global business and conduct business in various currencies around the world. We have exposure to foreign currency risk as fluctuations in foreign exchange rates impact our operating results as we translate the operating results from various functional currencies into the U.S. dollar reporting currency at the current average rates. We also record foreign exchange remeasurement gains and losses when business transactions are denominated in currencies other than the functional currency of that operation. The following table presents the exchange rates as of the end of each period and the average of the month-end exchange rates for the years ended March 31, 2014, 2013, and 2012:
Exchange Rate as of
March 31,
|
Average Exchange Rate
Year Ended March 31,
|
|||||||||||||||||
2014 |
2013 |
2012 |
2014 |
2013 |
2012 |
|||||||||||||
U.S. dollar per Euro |
1.378 |
1.282 |
1.335 |
1.344 |
1.289 |
1.385 |
||||||||||||
Brazilian real per U.S. dollar |
2.263 |
2.014 |
1.823 |
2.261 |
2.017 |
1.696 |
||||||||||||
South Korean won per U.S. dollar |
1,069 |
1,112 |
1,138 |
1,090 |
1,115 |
1,111 |
||||||||||||
Canadian dollar per U.S. dollar |
1.104 |
1.016 |
0.997 |
1.058 |
1.003 |
0.992 |
In fiscal 2014, the U.S. dollar was stronger on average against the Brazilian real and Canadian dollar, while it was weaker against the Euro and South Korean won, as compared to fiscal 2013. In Europe, the weaker U.S. dollar resulted in favorable foreign exchange translation when comparing fiscal 2014 operating results with fiscal 2013, as these operations are recorded in their local currency and translated into the U.S. dollar reporting currency. In South Korea, the change in rates had an immaterial impact on results when compared to prior year. In Brazil and Canada, the U.S. dollar is the functional currency due to predominantly U.S. dollar selling prices while our operating costs are predominately denominated in the Brazilian real and the Canadian dollar. The stronger U.S. dollar compared to the Brazilian real and the Canadian dollar resulted in a favorable remeasurement of our operating costs into the U.S. dollar in fiscal 2014 compared to fiscal 2013.
We use foreign exchange forward contracts and cross-currency swaps to manage our exposure to changes in exchange rates. These exposures arise from recorded assets and liabilities, firm commitments and forecasted cash flows denominated in currencies other than the functional currency of certain operations, which includes capital expenditures and net investment in foreign subsidiaries.
The impact of foreign exchange remeasurement, net of the related hedges, was a net gain of $7 million in fiscal 2014 and a net gain of $10 million in fiscal 2013 due primarily to gains on the Brazilian real denominated liabilities being remeasured to the U.S. dollar, partially offset by our hedging losses on these liabilities. For other foreign currency hedging programs, the unrealized gains or losses on undesignated derivatives are recognized in the statement of operations prior to the hedged transaction. The movement of currency exchange rates during fiscal 2014 and fiscal 2013 resulted in $3 million and $14 million of unrealized losses on undesignated foreign currency derivatives (excluding balance sheet remeasurement hedges), respectively, which were not recognized in the statement of operations in the same period as the hedged transaction.
See Segment Review below for the impact of foreign currency on each of our segments.
34
Results of Operations
Year Ended March 31, 2014 Compared with the Year Ended March 31, 2013
"Net sales" were $9.8 billion, which was flat compared to the prior year. Factors impacting "Net sales" include a 10% decrease in average aluminum prices, lower sales due to the sale of three foil and packaging plants in Europe in the prior year, and a decline in conversion premiums in our can products driven by global competitive market conditions, which were offset by higher shipments of automotive, can and non-FRP, and favorable foreign currency translation.
“Cost of goods sold (exclusive of depreciation and amortization)” was $8.5 billion, which was flat compared to the prior year. Factors impacting "Cost of goods sold (exclusive of depreciation and amortization)" include lower average aluminum prices, cost reductions from utilizing more recycled metal, incremental costs we incurred in the prior year related to supply disruptions from our ERP implementation that didn't recur this year, cost reductions due to an amendment we made to a non-union retiree medical plan in the current year, and lower costs due to the sale of three foil and packaging plants in Europe in the prior year. Offsetting these declines were higher total shipments, reduction in the benefits from utilizing recycled metal due to lower average aluminum prices and a reduction in the discount off primary aluminum prices for the procurement of recycled metal. Total metal input costs included in "Cost of goods sold (exclusive of depreciation and amortization)” declined $176 million.
“Income before income taxes” for the year ended March 31, 2014 was $115 million, which compared to $286 million reported in the year ended March 31, 2013. In addition to the factors noted above, the following items affected “Income before income taxes:”
• |
"Selling, general and administrative expenses" increased $63 million primarily due to higher annual and long term incentive costs;
|
• |
“Depreciation and amortization” increased by $42 million due to the recent commissioning of some of our global expansion projects and accelerated depreciation on certain non-core assets;
|
• |
"Gain on assets held for sale" of $6 million for the year ended March 31, 2014, relates to real property we sold in Brazil, while the $3 million gain for the year ended March 31, 2013 relates to the disposal of three foil rolling and packaging operations in Europe;
|
• |
"Loss on extinguishment of debt" of $7 million for the year ended March 31, 2013 related to the refinancing transaction we completed on our Term Loan Facility in prior year;
|
• |
“Restructuring and impairment, net” of $75 million for the year ended March 31, 2014, is related to $36 million of impairment, severance, and environmental charges related to our non-core assets in Brazil; $27 million of severance charges and a pension curtailment loss related to continuing efforts to reduce the cost of our business support organization for the European region; and $12 million of other impairment and restructuring charges. In the prior year, we incurred $47 million which is related to $9 million of severance and other shut-down costs associated with our pot-line closure in Brazil; $8 million related to severance and pension settlement charges we incurred in the closure of our Saguenay Works plant in Quebec, Canada; $8 million of severance and moving charges related to the closure of a research and development center in Kingston, Ontario; $8 million of severance related to the efforts to reduce the cost of our business support organization in Europe; and $13 million of other impairment and restructuring charges. (see Note 2 — Restructuring and impairment to our accompanying audited consolidated financial statements for further details on restructuring activities);
|
• |
An $11 million gain on business interruption insurance recovery for the year ended March 31, 2013, related to an insurance settlement for lost business as a result of a fire at a customer's plant, which is reported as "Other income, net"; and |
• |
Unrealized losses of $10 million for the year ended March 31, 2014 comprised of changes in fair value of undesignated derivatives other than foreign currency remeasurement hedging activities as compared to $14 million of gains in prior year, which is reported in "Other income, net."
|
Our effective tax rate for the year ended March 31, 2014 was 9%, compared to 27% for the year ended March 31, 2013. The effective tax rate was lower in the current year primarily due to lower pre-tax income, higher tax credits, and the release of certain deferred tax asset valuation allowances.
We reported “Net income attributable to our common shareholder” of $104 million for the year ended March 31, 2014 as compared to $202 million for the year ended March 31, 2013, primarily as a result of the factors discussed above.
35
Segment Review
Due in part to the regional nature of supply and demand of aluminum rolled products and in order to best serve our customers, we manage our activities on the basis of geographical regions and are organized under four operating segments: North America, Europe, Asia and South America.
We measure the profitability and financial performance of our operating segments based on “Segment income.” “Segment income” provides a measure of our underlying segment results that is in line with our approach to risk management. We define “Segment income” as earnings before (a) “depreciation and amortization”; (b) “interest expense and amortization of debt issuance costs”; (c) “interest income”; (d) unrealized gains (losses) on change in fair value of derivative instruments, net, except for foreign currency remeasurement hedging activities, which are included in segment income; (e) impairment of goodwill; (f) gain or loss on extinguishment of debt; (g) noncontrolling interests’ share; (h) adjustments to reconcile our proportional share of “Segment income” from non-consolidated affiliates to income as determined on the equity method of accounting; (i) “restructuring and impairment, net”; (j) gains or losses on disposals of property, plant and equipment and businesses, net; (k) other costs, net; (l) litigation settlement, net of insurance recoveries; (m) sale transaction fees; (n) provision or benefit for taxes on income (loss) and (o) cumulative effect of accounting change, net of tax. The financial information for our segments includes the results of our affiliates on a proportionately consolidated basis, which is consistent with the way we manage our business segments. See Note 8 — Consolidation and Note 9 — Investment in and Advances to Non-Consolidated Affiliates and Related Party Transactions for further information about these affiliates. Our presentation of “Segment income” on a consolidated basis is a non-GAAP financial measure. See “Non-GAAP Financial Measures” below for additional discussion about our use of total “Segment income.”
The tables below show selected segment financial information (in millions, except shipments which are in kt). For additional financial information related to our operating segments, see Note 21 — Segment, Major Customer and Major Supplier Information. In order to reconcile the financial information for the segments shown in the tables below to the relevant U.S. GAAP-based measures, "Eliminations and other" must adjust for proportional consolidation of each line item, and eliminate intersegment shipments (in kt) and intersegment "Net sales."
Selected Operating Results
Year Ended March 31, 2014
|
North
America
|
Europe |
Asia |
South
America
|
Eliminations and other |
Total |
||||||||||||||||||
Net sales |
$ |
3,050 |
$ |
3,280 |
$ |
1,876 |
$ |
1,588 |
$ |
(27 |
) |
$ |
9,767 |
|||||||||||
Shipments |
||||||||||||||||||||||||
Rolled products - third party |
956 |
877 |
630 |
432 |
— |
2,895 |
||||||||||||||||||
Rolled products - intersegment |
2 |
34 |
10 |
15 |
(61 |
) |
— |
|||||||||||||||||
Total Rolled Products |
958 |
911 |
640 |
447 |
(61 |
) |
2,895 |
|||||||||||||||||
Non-rolled products |
36 |
66 |
— |
87 |
(23 |
) |
166 |
|||||||||||||||||
Total shipments |
994 |
977 |
640 |
534 |
(84 |
) |
3,061 |
Selected Operating Results
Year Ended March 31, 2013
|
North
America
|
Europe |
Asia |
South
America
|
Eliminations and other |
Total |
||||||||||||||||||
Net sales |
$ |
3,405 |
$ |
3,181 |
$ |
1,762 |
$ |
1,391 |
$ |
73 |
$ |
9,812 |
||||||||||||
Shipments |
||||||||||||||||||||||||
Rolled products - third party |
988 |
847 |
556 |
395 |
— |
2,786 |
||||||||||||||||||
Rolled products - intersegment |
2 |
14 |
6 |
— |
(22 |
) |
— |
|||||||||||||||||
Total Rolled Products |
990 |
861 |
562 |
395 |
(22 |
) |
2,786 |
|||||||||||||||||
Non-rolled products |
22 |
58 |
— |
76 |
(12 |
) |
144 |
|||||||||||||||||
Total shipments |
1,012 |
919 |
562 |
471 |
(34 |
) |
2,930 |
36
The following table reconciles changes in “Segment income” for the year ended March 31, 2013 to the year ended March 31, 2014 (in millions).
Changes in Segment income |
North
America
|
Europe (A) |
Asia |
South
America
|
Total |
|||||||||||||||
Segment Income - Year Ended March 31, 2013 |
$ |
324 |
$ |
261 |
$ |
174 |
$ |
202 |
$ |
961 |
||||||||||
Volume |
(35 |
) |
49 |
31 |
38 |
83 |
||||||||||||||
Conversion premium and product mix |
(38 |
) |
(59 |
) |
(31 |
) |
(1 |
) |
(129 |
) |
||||||||||
Conversion costs (B) |
— |
31 |
— |
(17 |
) |
14 |
||||||||||||||
Metal price lag |
(3 |
) |
(9 |
) |
5 |
1 |
(6 |
) |
||||||||||||
Foreign exchange |
(6 |
) |
9 |
(1 |
) |
17 |
19 |
|||||||||||||
Primary metal production |
— |
— |
— |
15 |
15 |
|||||||||||||||
Selling, general & administrative and research & development costs (C) |
(2 |
) |
(23 |
) |
(17 |
) |
(22 |
) |
(64 |
) |
||||||||||
Other changes |
(11 |
) |
6 |
(1 |
) |
(2 |
) |
(8 |
) |
|||||||||||
Segment Income - Year Ended March 31, 2014 |
$ |
229 |
$ |
265 |
$ |
160 |
$ |
231 |
$ |
885 |
(A) |
Included in the Europe "Segment income" for the year ended March 31, 2013, were the operating results of three foil and packaging plants (Rugles, France; Dudelange, Luxembourg; and Berlin, Germany) that we sold on June 28, 2012. The change to "Segment income" attributable to these three foil plants for the year ended March 31, 2014 compared to the prior year was unfavorable by $1 million. The following table reconciles changes in “Segment income” for the year ended March 31, 2013 to the year ended March 31, 2014 (in millions), with the impact of the foil and packaging plants separately identified.
|
Changes in Segment income |
Europe |
Total |
||||||
Segment Income - Year Ended March 31, 2013 |
$ |
261 |
$ |
961 |
||||
Volume |
63 |
97 |
||||||
Conversion premium and product mix |
(34 |
) |
(104 |
) |
||||
Conversion costs |
(4 |
) |
(21 |
) |
||||
Metal price lag |
(10 |
) |
(7 |
) |
||||
Foreign exchange |
10 |
20 |
||||||
Primary metal production |
— |
15 |
||||||
Selling, general & administrative and research & development costs |
(26 |
) |
(67 |
) |
||||
Other changes |
6 |
(8 |
) |
|||||
Net impact of three foil plants sold in fiscal 2013 |
(1 |
) |
(1 |
) |
||||
Segment Income - Year Ended March 31, 2014 |
$ |
265 |
$ |
885 |
(B) |
Conversion costs include expenses incurred in production such as direct and indirect labor, energy, freight, recycled metal usage, alloys and hardeners, coatings, alumina, melt loss, the benefit of utilizing recycled metal and other metal costs. Fluctuations in this component reflect cost efficiencies (inefficiencies) during the period as well as cost (inflation) deflation. |
(C) |
Selling, general & administrative costs and research & development costs include costs incurred directly by each segment and all corporate related costs, which are allocated to each of our segments. These costs increased in fiscal 2014 compared to fiscal 2013 for the following reasons: 1) higher employee incentive costs attributable to the modification of our long term incentive plan, 2) higher valuation of the Company's long term incentive awards indexed in Hindalco's stock price, 3) higher annual employee incentive costs, and 4) wage inflation. Other significant fluctuations are discussed below.
|
37
North America
“Net sales” declined $355 million, or 10%, reflecting a decline in our can volumes, lower conversion premiums, and lower average price of aluminum, partially offset by increases in our automotive and light gauge product shipments. Excess capacity in the can market in North America has negatively impacted our volumes and resulted in competitive pricing pressures we experienced with the renewal of existing customers' supply contracts at the end of the prior fiscal year. We continue to experience an increase in demand and shipments of our automotive products.
“Segment income” was $229 million, down 29%, reflecting the items above, as well as, unfavorable metal price lag, higher general and administrative costs, and an unfavorable foreign currency impact. Conversion costs were flat compared to prior year. Conversion costs were favorably impacted by a reduction in employee benefit costs in the current year due to an amendment made to our non-union U.S. retiree medical plan and the prior year production and supply chain issues we experienced with our ERP implementation and transferring our Saguenay plant capacity to other North America plants. Conversion costs were unfavorably impacted by a reduction in the benefits from the utilization of recycled metal, higher energy costs, and higher fixed costs associated with the commissioning of our automotive lines. Metal price lag was unfavorable due to an increase in certain metal procurement costs. General and administrative costs were slightly higher due to an increase in employee incentive costs offset by an increase in the capitalization of labor costs in the current year related to our automotive expansion project. Other changes include an $11 million insurance settlement gain in the prior year that did not recur in the current period.
We began the commissioning phase of two automotive sheet finishing lines at our Oswego, New York facility in July 2013, which will result in approximately 240 kt of additional automotive finishing capacity annually when it is operating at full capacity. In December 2013, we announced plans to build a third automotive finishing line in our Oswego, New York facility, which will add an additional 120 kt of finishing capacity. The third line is expected to become operational at the end of calendar year 2015.
Europe
“Net sales” increased $99 million, or 3%, reflecting higher total shipments, partially offset by lower average aluminum prices and lower conversion premiums. Higher shipments of flat rolled products were driven by our automotive and can products, partially offset by declines in light gauge and industrial products. The reduction in shipments of our light gauge products was due to the sale of our European aluminum foil and packaging rolling plants in June of 2012. Our conversion premiums declined as a result of competitive market conditions that resulted in lower can prices and a shift in product mix due to the sale of three European foil and packaging plants in the prior year, and lower prices on certain intersegment shipments.
“Segment income” was $265 million, which is slightly higher than prior year reflecting the factors above, as well as unfavorable metal price lag and higher general and administrative costs, partially offset by lower conversion costs and favorable foreign currency translation. Excluding the impact of the conversion costs of the three European foil and packaging plants which we sold, conversion costs were unfavorable due to higher employment and freight costs, partially offset by an increase in the benefits from utilization of recycled metal and reductions in certain metal procurement costs. General and administrative costs increased due to higher employee incentive costs. Metal price lag was unfavorable due primarily to gains we realized in the prior year and an increase in other metal costs.
We are building a fully integrated recycling facility at our Nachterstedt, Germany plant, which will have an annual capacity of approximately 400 kt when operating at full capacity. The recycling facility is expected to begin commissioning in the middle of calendar year 2014. In December 2013, we announced plans to build a second automotive finishing line in our Nachterstedt, Germany facility, which will add an additional 120 kt of finishing capacity. The second line is expected to become operational at the end of calendar year 2015.
38
Asia
“Net sales” increased $114 million, or 6%, reflecting higher shipments of our can products, partially offset by declines in our foil stock products, lower average prices of aluminum, and lower conversion premiums. The increase in our can volumes were driven by our Asia segment shipping more can products to customers in the Middle East. We are facing more competition, primarily from FRP suppliers in China, who are able to price their metal off the Shanghai Futures Exchange, which does not have a local market premium. We price our metal based on the LME, which charges a local market premium resulting in significant pressure on the the conversion premiums we charge our customers. Conversion premiums were also lower due to unfavorable product mix compared to prior year.
“Segment income” was $160 million, down 8%, reflecting the items above, as well as higher general and administrative expenses, partially offset by favorable metal price lag. General and administrative costs were higher due to an increase in employee incentive costs and increased headcount for our Middle East operations, our new Vietnam recycling center, and the construction of our new automotive sheet finishing plant in China. Our conversion costs were relatively flat compared to prior year and reflect a favorable impact from the use of more recycled metal through our new recycling capabilities in our Yeongju, South Korea facility partially offset by higher employment, freight, and energy costs.
In June 2013, we commissioned our first recycling collection center in Ho Chi Minh City, Vietnam, which handles the procurement, cleaning and baling of UBCs and supplies the UBCs to our recycling facility in Yeongju, South Korea. In July 2013, we began the commissioning phase of our new rolling facilities in South Korea which will result in approximately 350 kt of additional capacity when operating at full capacity. Our automotive sheet finishing plant in Changzhou, China, which will have annual capacity of approximately 120 kt when operating at full capacity, is expected to begin commissioning in the middle of calendar year 2014.
South America
“Net sales” increased $197 million, or 14%, due to both higher flat rolled and non-flat rolled product volumes and higher conversion premiums, partially offset by lower average prices of aluminum. Shipments of our can products increased compared to prior year due to an increase in can demand combined with the additional rolling capacity that we added with the expansion of our Pinda facility. Shipments of our non-flat rolled products increased due to higher alumina and billet sales from our primary metal production operations.
“Segment income” was $231 million, up 14%, reflecting the items above, as well as favorable foreign currency impact, partially offset by higher conversion costs and general and administrative costs. Conversion costs were unfavorable due to wage inflation, higher headcount, higher market premiums on the procurement of metal, higher freight costs, and an increase in repairs and maintenance, partially offset by reductions in other metal procurement costs and favorable benefits from the utilization of recycled metal. General and administrative costs increased due to higher employee incentive costs and higher working capital financing costs.
Our recently completed rolling expansion in our Pinda facility will result in approximately 220 kt of additional rolling capacity annually when the facility is operating at full capacity. Additionally, we are installing a new coating line for beverage can end stock to increase our can coating capacity by approximately 100 kt annually and expanding our recycling capacity by approximately 190 kt in our Pinda facility, both of which began the commissioning process in early calendar year 2014. In March 2013, we shut down one of our two primary aluminum smelter lines in Brazil, as we continue to increase the use of recycled metal over primary metal. In March 2014, we made a decision to sell our hydroelectric power generation operations and in April 2014 we entered into an agreement with a third party to sell these operations, pending regulatory approval.
39
Reconciliation of segment results to “Net income attributable to our common shareholder”
Costs such as depreciation and amortization, interest expense and unrealized gains (losses) on changes in the fair value of derivatives (except for derivatives used to manage our foreign currency remeasurement activities) are not utilized by our chief operating decision maker in evaluating segment performance. The table below reconciles income from reportable segments to “Net income attributable to our common shareholder” for the years ended March 31, 2014 and 2013 (in millions).
Year ended March 31, |
|||||||
2014 |
2013 |
||||||
North America |
$ |
229 |
$ |
324 |
|||
Europe |
265 |
261 |
|||||
Asia |
160 |
174 |
|||||
South America |
231 |
202 |
|||||
Total Segment income |
885 |
961 |
|||||
Depreciation and amortization |
(334 |
) |
(292 |
) |
|||
Interest expense and amortization of debt issuance costs |
(304 |
) |
(298 |
) |
|||
Adjustment to eliminate proportional consolidation |
(40 |
) |
(41 |
) |
|||
Unrealized (losses) gains on change in fair value of derivative instruments, net |
(10 |
) |
14 |
||||
Realized gains on derivative instruments not included in segment income |
5 |
5 |
|||||
Loss on extinguishment of debt |
— |
(7 |
) |
||||
Restructuring and impairment, net |
(75 |
) |
(47 |
) |
|||
Gain on assets held for sale |
6 |
3 |
|||||
Other costs, net |
(18 |
) |
(12 |
) |
|||
Income before income taxes |
115 |
286 |
|||||
Income tax provision |
11 |
83 |
|||||
Net income |
104 |
203 |
|||||
Net income attributable to noncontrolling interests |
— |
1 |
|||||
Net income attributable to our common shareholder |
$ |
104 |
$ |
202 |
"Depreciation and amortization” increased by $42 million due to new depreciable assets including our rolling expansion project in Pinda, Brazil; our rolling expansion in South Korea; our recycling expansion in Yeongju, South Korea; and amortization of our new ERP system, as well as accelerated depreciation on certain non-core assets.
“Adjustment to eliminate proportional consolidation” typically relates to depreciation and amortization and income taxes at our Aluminium Norf GmbH (Alunorf) joint venture. Income taxes related to our equity method investments are reflected in the carrying value of the investment and not in our consolidated “Income tax provision.”
"Other costs, net" related primarily to losses on the disposal of assets and certain indirect tax expenses in Brazil, partially offset by interest income.
40
Year Ended March 31, 2013 Compared with the Year Ended March 31, 2012
Our performance in fiscal 2013 was negatively impacted by pricing pressures from competitors, supply chain disruptions due to the implementation of a new ERP system in two North America plants, as well as production challenges and softer demand. Shipments of our flat rolled products declined to 2,786 kt for the year ended March 31, 2013, compared to 2,838 kt in prior year. “Net sales” were 11% lower primarily driven by a 15% decline in average aluminum prices and a decline in our flat rolled product volumes by 2%.
“Cost of goods sold (exclusive of depreciation and amortization)” declined $1.3 billion, or 13%, due primarily due to lower average aluminum prices and an overall decline in shipments, partially offset by higher costs associated with the production and supply chain disruptions we experienced in North America. Our metal input costs declined $1.0 billion, which reflects the lower average aluminum prices and lower volumes.
"Net sales" and "Cost of goods sold (exclusive of depreciation and amortization)" include the results of three European foil and packaging plants for fiscal 2012 and the first three months of fiscal 2013 until they were sold in June 2012. The sale of the three plants reduced Europe's "Segment income" by $7 million in fiscal 2013 compared to prior year.
“Income before income taxes” for the year ended March 31, 2013 was $286 million, which compared to $129 million reported in the year ended March 31, 2012. In addition to the factors noted above, the following items affected “Income before income taxes:”
• |
"Selling, general and administrative expenses" increased $15 million as a result of higher start-up costs related to our strategic expansion projects, higher costs of implementing a new ERP system and wage inflation and pension costs, offset by cost cutting initiatives we implemented in the second half of fiscal 2013 and lower employee incentives; |
• |
“Depreciation and amortization” declined by $37 million as a result of groups of our fixed assets reaching their fully depreciated balances and certain facilities being closed or divested in the past year; |
• |
“Restructuring and impairment, net” of $47 million for the year ended March 31, 2013, related primarily to severance and pension settlement charges we incurred in the closure of our Saguenay Works plant in Quebec, Canada; severance and moving charges related to the closure of a research and development center in Kingston, Ontario; severance and other shut-down costs associated with our pot-line closure in Brazil; and other severance charges in Europe. "Restructuring and impairment, net" of $64 million in the year ended March 31, 2012 related primarily to an impairment on our Saguenay plant; severance across our European plants; and restructuring at our Santo Andre plant in Brazil; partially offset by the reversal of outstanding environmental contingencies of $21 million related to the final sale of the Rogerstone facility, which were assumed by the buyer (see Note 2 — Restructuring and impairment to our accompanying audited consolidated financial statements for further details on restructuring activities); |
• |
We estimated and recorded a $111 million “Loss on assets held for sale” for the year ended March 31, 2012 related to the planned sale of three foil and packaging plants in Rugles, France; Dudelange, Luxembourg; and Berlin, Germany. In June 2012, we completed the sale of the plants to Eurofoil, a unit of AIAC, which resulted in a $3 million "Gain on assets held for sale" for the year ended March 31, 2013; |
• |
An $11 million gain on business interruption insurance recovery for the year ended March 31, 2013, related to an insurance settlement for lost business as a result of a fire at a customer's plant, which is reported as "Other income, net"; and |
• |
Unrealized gains of $14 million for the year ended March 31, 2013 comprised of changes in fair value of undesignated derivatives other than foreign currency remeasurement hedging activities as compared to $62 million of losses in prior year, which is reported in "Other income, net." The reduction in this volatility is the result of the Company's implementation of hedge accounting for our derivative transactions. |
Our effective tax rate for the year ended March 31, 2013 and 2012 was 27%.
"Net income attributable to noncontrolling interests" declined $26 million as we acquired outstanding shares of our South Korea subsidiary, increasing our ownership percentage to over 99%.
We reported “Net income attributable to our common shareholder” of $202 million for the year ended March 31, 2013 as compared to $63 million for the year ended March 31, 2012, primarily as a result of the factors discussed above.
41
Segment Review
Due in part to the regional nature of supply and demand of aluminum rolled products and in order to best serve our customers, we manage our activities on the basis of geographical regions and are organized under four operating segments: North America, Europe, Asia and South America.
Selected Operating Results Year Ended March 31, 2013 |
North
America
|
Europe |
Asia |
South
America
|
Eliminations and other |
Total |
||||||||||||||||||
Net sales |
$ |
3,405 |
$ |
3,181 |
$ |
1,762 |
$ |
1,391 |
$ |
73 |
$ |
9,812 |
||||||||||||
Shipments |
||||||||||||||||||||||||
Rolled products - third party |
988 |
847 |
556 |
395 |
— |
2,786 |
||||||||||||||||||
Rolled products - intersegment |
2 |
14 |
6 |
— |
(22 |
) |
— |
|||||||||||||||||
Total rolled products |
990 |
861 |
562 |
395 |
(22 |
) |
2,786 |
|||||||||||||||||
Non-rolled products |
22 |
58 |
— |
76 |
(12 |
) |
144 |
|||||||||||||||||
Total shipments |
1,012 |
919 |
562 |
471 |
(34 |
) |
2,930 |
Selected Operating Results Year Ended March 31, 2012 |
North
America
|
Europe |
Asia |
South
America
|
Eliminations and other |
Total |
||||||||||||||||||
Net sales |
$ |
3,967 |
$ |
3,840 |
$ |
1,830 |
$ |
1,278 |
$ |
148 |
$ |
11,063 |
||||||||||||
Shipments: |
||||||||||||||||||||||||
Rolled products - third party |
1,064 |
875 |
524 |
375 |
— |
2,838 |
||||||||||||||||||
Rolled products - intersegment |
— |
1 |
— |
— |
(1 |
) |
— |
|||||||||||||||||
Total rolled products |
1,064 |
876 |
524 |
375 |
(1 |
) |
2,838 |
|||||||||||||||||
Non-rolled products |
15 |
89 |
12 |
42 |
(14 |
) |
144 |
|||||||||||||||||
Total shipments |
1,079 |
965 |
536 |
417 |
(15 |
) |
2,982 |
The following table reconciles changes in “Segment income” for the year ended March 31, 2012 to the year ended March 31, 2013 (in millions).
Changes in Segment Income |
North
America
|
Europe (A) |
Asia |
South
America
|
Total |
|||||||||||||||
Segment Income - Year Ended March 31, 2012 |
$ |
407 |
$ |
284 |
$ |
181 |
$ |
181 |
$ |
1,053 |
||||||||||
Volume |
(65 |
) |
(15 |
) |
22 |
16 |
(42 |
) |
||||||||||||
Conversion premium and product mix |
50 |
(105 |
) |
(18 |
) |
(7 |
) |
(80 |
) |
|||||||||||
Conversion costs (B) |
(80 |
) |
116 |
7 |
13 |
56 |
||||||||||||||
Metal price lag |
14 |
6 |
(3 |
) |
(2 |
) |
15 |
|||||||||||||
Foreign exchange |
7 |
(20 |
) |
— |
(3 |
) |
(16 |
) |
||||||||||||
Primary metal production |
— |
— |
— |
6 |
6 |
|||||||||||||||
Selling, general & administrative and research & development costs (C) |
(19 |
) |
3 |
(13 |
) |
(2 |
) |
(31 |
) |
|||||||||||
Other changes |
10 |
(8 |
) |
(2 |
) |
— |
— |
|||||||||||||
Segment Income - Year Ended March 31, 2013 |
$ |
324 |
$ |
261 |
$ |
174 |
$ |
202 |
$ |
961 |
42
(A) |
Included in the Europe "Segment income" for the year ended March 31, 2012 and the three months ended June 30, 2012 were the operating results of three foil and packaging plants (Rugles, France; Dudelange, Luxembourg; and Berlin, Germany) that we sold on June 28, 2012. The change to "Segment income" attributable to these three foil plants for the year ended March 31, 2013 compared to the prior year was unfavorable by $7 million. The following table reconciles changes in “Segment income” for the year ended March 31, 2012 to the year ended March 31, 2013 (in millions), with the impact of the foil and packaging plants separately identified. |
Changes in Segment income |
Europe |
Total |
||||||
Segment income - Year Ended March 31, 2012 |
$ |
284 |
$ |
1,053 |
||||
Volume |
19 |
(8 |
) |
|||||
Conversion premium and product mix |
(25 |
) |
— |
|||||
Conversion costs |
18 |
(42 |
) |
|||||
Metal price lag |
6 |
15 |
||||||
Foreign exchange |
(18 |
) |
(14 |
) |
||||
Primary metal production |
— |
6 |
||||||
Selling, general & administrative and research & development costs |
(8 |
) |
(42 |
) |
||||
Other changes |
(8 |
) |
— |
|||||
Net impact of three foil plants sold in fiscal 2013 |
(7 |
) |
(7 |
) |
||||
Segment income - Year Ended March 31, 2013 |
$ |
261 |
$ |
961 |
(B) |
Conversion costs include expenses incurred in production such as direct and indirect labor, energy, freight, scrap usage, alloys and hardeners, coatings, alumina, melt loss, the benefit of UBCs and other metal costs. Fluctuations in this component reflect cost efficiencies (inefficiencies) during the period as well as cost (inflation) deflation. |
(C) |
Selling, general & administrative costs and research & development costs include costs incurred directly by each segment and all corporate related costs, which are allocated to each of our segments. These costs increased in fiscal 2013 compared to fiscal 2012 for the following reasons: 1) higher costs of implementing a new ERP system; 2) higher start-up costs associated with our various strategic investment projects; and 3) higher wage inflation and pension costs, partially offset by lower employee incentives and cost cutting initiatives implemented in the second half of fiscal 2013. Other significant fluctuations are discussed below. |
North America
“Net sales” for the year ended March 31, 2013 were down $562 million, or 14%, as compared to the year ended March 31, 2012 reflecting lower volumes of our flat rolled products and lower average prices of aluminum. Shipments of our can and light gauge products were lower, partially offset by higher shipments of our automotive products. Our volumes were unfavorable in fiscal 2013 compared to fiscal 2012 due to lower shipments with a key customer, production and supply chain issues we experienced related to transferring our Saguenay plant capacity to other North America plants, and production and supply chain disruptions we experienced with our ERP implementation in the third quarter of fiscal 2013.
“Segment income” for the year ended March 31, 2013 was $324 million, down 20% as compared to the same period in the prior year, driven by lower volumes, higher conversion costs, and higher general and administrative costs, partially offset by favorable conversion premiums and favorable metal price lag. Our conversion costs were negatively impacted by higher freight and tolling costs, higher usage of sheet ingots due to the closure of our Saguenay plant and a reduction in the benefits from the utilization of scrap due to lower average aluminum prices and using less scrap metal in our production process. We also incurred an increase in costs and lost sales due to disruptions we experienced in our production and supply chain as a result of our ERP implementation, which negatively impacted our "Segment income" by approximately $40 million. We experienced disruptions in our Oswego plant during the fourth quarter of fiscal 2013 due to a fire, which negatively impacted our "Segment income" by approximately $9 million. Our conversion premiums were favorable in the first nine months of fiscal 2013 compared to prior year, but declined in the fourth quarter due to pricing pressures we are experiencing with the renewal of existing customers' supply contracts. Other changes to "Segment income" include the recognition of an $11 million gain in the third quarter of fiscal 2013 related to a business interruption insurance settlement, which was the result of lost business when one of our customer's plants was destroyed by a fire.
43
Europe
“Net sales” for the year ended March 31, 2013 were down $659 million, or 17%, as compared to the year ended March 31, 2012 reflecting lower average prices of aluminum and lower shipments of flat rolled products. We experienced lower volumes due to the sale of the European foil and packaging plants in June 2012 and lower volumes in industrial and lithographic products, partially offset by higher volumes in our can and automotive products.
“Segment income” for the year ended March 31, 2013 was $261 million, down 8% compared to the same period in the prior year. Our fiscal 2013 "Segment income" was negatively impacted by the sale of the European foil and packaging plants in June 2012, when compared to fiscal 2012 "Segment income" by $7 million. Excluding the impact from the European foil and packaging plants, we experienced an unfavorable shift in product mix to products that have lower conversion premiums, the impact of a weaker euro compared to the U.S. dollar, and an increase in general and administrative costs, partially offset by higher volumes of our can and automotive products and lower conversion costs. The favorable change in conversion costs was the result of favorable discounts on the procurement of scrap metal. Conversion costs were also favorable due to lower tolling and contractor costs, partially offset by higher employment costs, higher natural gas costs, and higher freight costs.
Asia
“Net sales” for the year ended March 31, 2013 were down $68 million, or 4%, as compared to the year ended March 31, 2012 reflecting lower average aluminum prices and lower conversion premiums, partially offset by higher shipments of flat rolled products. We experienced higher volumes in our can and automotive products, partially offset by a decline in foil stock products.
“Segment income” for the year ended March 31, 2013 was $174 million, down 4% compared to the same period of the prior year, driven by lower conversion premiums, unfavorable metal price lag, and higher general and administrative costs, partially offset by an increase in volumes and lower conversion costs. The local market premium on aluminum has increased significantly in Asia, which has put pressure on our conversion margins and we are experiencing more competition, primarily from FRP suppliers in China. General and administrative costs were higher compared to prior year, due to increased headcount for our new Vietnam recycling center, which will come on-line in June 2013, and our new heat treatment plant in China, which broke ground in October 2012. Conversion costs were favorable compared to prior year due to a higher usage of scrap and higher discounts off prime aluminum we paid for scrap metal, partially offset by higher prices for electricity, natural gas, and oil.
South America
“Net sales” for the year ended March 31, 2013 were up $113 million, or 9%, as compared to the year ended March 31, 2012 reflecting higher shipments of our flat and non-flat rolled products, partially offset by lower average prices of aluminum. We experienced a favorable increase in our shipments of our can products, partially offset by declines in our products for industrial applications.
“Segment income” for South America was $202 million, up 12%, in the year ended March 31, 2013 compared to the same period in prior year, due to an increase in volumes, lower conversion costs and favorable impact of foreign currency rates on our primary business, partially offset by unfavorable conversion premiums, unfavorable metal price lag and higher general and administrative costs. Conversion costs were lower due to higher discounts off prime aluminum we paid for scrap metal, a reduction in melt loss, and reduced tolling costs, partially offset by higher labor and maintenance costs and less usage of scrap in our production process. Conversion premiums were unfavorable due to a decline in prices of our products for industrial applications.
44
Reconciliation of segment results to “Net income attributable to our common shareholder”
Costs such as depreciation and amortization, interest expense and unrealized gains (losses) on changes in the fair value of derivatives, except foreign currency derivatives on our foreign currency balance sheet exposures, are not utilized by our chief operating decision maker in evaluating segment performance. The table below reconciles “Segment income” from reportable segments to “Net income attributable to our common shareholder” for the year ended March 31, 2013 and 2012 (in millions).
Year Ended March 31, |
|||||||
2013 |
2012 |
||||||
North America |
$ |
324 |
$ |
407 |
|||
Europe |
261 |
284 |
|||||
Asia |
174 |
181 |
|||||
South America |
202 |
181 |
|||||
Total Segment income |
961 |
1,053 |
|||||
Depreciation and amortization |
(292 |
) |
(329 |
) |
|||
Interest expense and amortization of debt issuance costs |
(298 |
) |
(305 |
) |
|||
Adjustment to eliminate proportional consolidation |
(41 |
) |
(49 |
) |
|||
Unrealized gains (losses) on change in fair value of derivative instruments, net |
14 |
(62 |
) |
||||
Realized gains on derivative instruments not included in segment income |
5 |
1 |
|||||
Loss on extinguishment of debt |
(7 |
) |
— |
||||
Restructuring and impairment, net |
(47 |
) |
(64 |
) |
|||
Gain (loss) on assets held for sale |
3 |
(111 |
) |
||||
Other costs, net |
(12 |
) |
(5 |
) |
|||
Income before income taxes |
286 |
129 |
|||||
Income tax provision |
83 |
39 |
|||||
Net income |
203 |
90 |
|||||
Net income attributable to noncontrolling interests |
1 |
27 |
|||||
Net income attributable to our common shareholder |
$ |
202 |
$ |
63 |
"Depreciation and amortization” declined by $37 million as a result of groups of our fixed assets reaching their fully depreciated balances and certain facilities being closed or divested in the past year. As disclosed in Note 2 - Restructuring Programs and Note 5 - Assets Held for Sale to our financial statements, the following facilities were either closed or divested in fiscal 2013 or fiscal 2012: a lithographic sheet line in Göttingen, Germany; the Saguenay Works facility in Quebec, Canada; one rolling mill in Santo Andre, Brazil; and three foil and packaging operations in Rugles, France; Dudelange, Luxembourg; and Berlin, Germany. As of March 31, 2013, all of these facilities had been either sold, scrapped or had been impaired to their estimated realizable values, which was close to zero.
“Unrealized gain (loss) on change in fair value of derivative instruments, net” is comprised of unrealized gains and losses on undesignated derivatives other than foreign currency remeasurement hedging activities. For the year ended March 31, 2013, we recorded a $14 million gain compared to a $62 million loss for the year ended March 31, 2012. The variance is the result of changes in the fair values of the derivative instruments and the implementation of hedge accounting.
Realized gains on derivative instruments not included in "Segment income" represents realized gains on foreign currency derivatives related to capital expenditures.
During the year ended March 31, 2013 we incurred a $7 million "Loss on extinguishment of debt" related to the refinancing transaction we completed on our Term Loan Facility.
"Other costs, net" related primarily to losses on the disposal of assets and indirect tax expenses in Brazil, partially offset by interest income.
45
Liquidity and Capital Resources
Over the past three years, we have been in a transitional period in which we invested heavily in strategically expanding rolling capacity, recycling operations and automotive finishing capabilities. Several of our expansion projects are ramping up operations, and we expect others to begin commissioning in the next year which, when operational, will generate additional operating cash flows. In addition to completing these projects, we have announced an additional expansion of our automotive sheet finishing capabilities in the U.S. and Germany. Our significant investments in the business were funded through cash flows generated by our operations, and a combination of local financing and our senior secured credit facilities. We expect to be able to fund our continued expansions, service our debt obligations and provide sufficient liquidity to run our business through the generation of operating cash flows and our debt facilities.
Available Liquidity
Our available liquidity as of March 31, 2014 and March 31, 2013 is as follows (in millions):
March 31, |
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2014 |
2013 |
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Cash and cash equivalents |
$ |
509 |
$ |