FORM 10-K
SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
| (Mark One) | ||
|
ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(D) OF THE SECURITIES EXCHANGE ACT OF 1934 |
For the fiscal year ended December 31, 2001.
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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:1-11311
LEAR CORPORATION
(Exact name of registrant as specified in its charter)
| Delaware | 13-3386776 | |
| (State or other jurisdiction of incorporation or organization) | (I.R.S. Employer Identification No.) | |
| 21557 Telegraph Road, Southfield, MI | 48086-5008 | |
| (Address of principal executive offices) | (zip code) |
Registrants telephone number, including area code: (248) 447-1500
Securities registered pursuant to Section 12(b) of the Act:
| Title of each class | Name of each exchange on which registered | |
| Common Stock, par value $.01 per share | New York Stock Exchange |
Securities registered pursuant to section 12(g) of the Act: None
Indicate by check mark whether the registrant (1) has filed all reports
required to be filed by section 13 or 15(d) of the Securities Exchange Act of
1934 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
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 registrants 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 _
As of March 1, 2002, the aggregate market value of the registrants Common Stock, par value $.01 per share, held by non-affiliates of the registrant was $2,967,092,254. The closing price of the Common Stock on March 1, 2002 as reported on the New York Stock Exchange was $46.29 per share.
As of March 1, 2002, the number of shares outstanding of the registrants Common Stock was 64,428,487 shares.
DOCUMENTS INCORPORATED BY REFERENCE
Certain sections of the registrants Notice of Annual Meeting of Stockholders and Proxy Statement for its Annual Meeting of Stockholders to be held on May 9, 2002, as described in the Cross-Reference Sheet and a Table of Contents included herewith, are incorporated by reference into Part III of this Report.
CROSS REFERENCE SHEET
AND
TABLE OF CONTENTS
| Page Number | ||||||
| or Reference (1) | ||||||
| PART I | ||||||
| ITEM | 1. | Business | 1 | |||
| ITEM | 2. | Properties | 8 | |||
| ITEM | 3. | Legal proceedings | 9 | |||
| ITEM | 4. | Submission of matters to a vote of security holders | 9 | |||
| PART II | ||||||
| ITEM | 5. | Market for the Companys common stock and related stockholder matters | 10 | |||
| ITEM | 6. | Selected financial data | 11 | |||
| ITEM | 7. | Managements discussion and analysis of financial condition and results of operations | 13 | |||
| ITEM | 7a. | Quantitative and Qualitative Disclosures about Market Risk (included in Item 7) | ||||
| ITEM | 8. | Consolidated financial statements and supplementary data | 24 | |||
| ITEM | 9. | Changes in and disagreements with accountants on accounting and financial disclosure | 66 | |||
| PART III | ||||||
| ITEM | 10. | Directors and Executive Officers of the Company (2) | 67 | |||
| ITEM | 11. | Executive compensation (3) | 70 | |||
| ITEM | 12. | Security ownership of certain beneficial owners and management (4) | 70 | |||
| ITEM | 13. | Certain relationships and related transactions (5) | 70 | |||
| PART IV | ||||||
| ITEM | 14. | Exhibits, financial statement schedule and reports on Form 8-K | 71 |
| (1) | Certain information is incorporated by reference, as indicated below, from the registrants Notice of Annual Meeting of Stockholders and Proxy Statement for its Annual Meeting of Stockholders to be held on May 9, 2002 (the Proxy Statement). | |
| (2) | A portion of the information required is incorporated by reference from the Proxy Statement sections entitled Election of Directors and Directors and Beneficial Ownership. | |
| (3) | Proxy Statement section entitled Executive Compensation. | |
| (4) | Proxy Statement section entitled Directors and Beneficial Ownership Security Ownership of Certain Beneficial Owners and Management. | |
| (5) | Proxy Statement section entitled Certain Transactions. |
PART I
ITEM 1 BUSINESS
In this Report, when we use the terms the Company, Lear, we, us and our, unless otherwise indicated or the context otherwise requires, we are referring to Lear Corporation and its consolidated subsidiaries. A substantial portion of the Companys operations are conducted through wholly-owned subsidiaries of Lear Corporation. Certain disclosures included in this Report constitute forward-looking statements that are subject to risk and uncertainty. See Managements Discussion and Analysis of Financial Condition and Results of Operations Forward-Looking Statements and Risk Factors.
BUSINESS OF THE COMPANY
General
We are the fifth largest automotive supplier in the world. We have grown
substantially over the last five years as a result of both internal growth and
acquisitions. Our sales have grown from $6.2 billion in 1996 to $13.6 billion
in 2001, a compound annual growth rate of 17%. We supply every major
automotive manufacturer in the world, including General Motors, Ford,
DaimlerChrysler, BMW, Fiat, Volkswagen, Peugeot, Renault, Toyota and Subaru.
We have established in-house capabilities in all five principal segments of the automotive interior market: seat systems; flooring and acoustic systems; door panels; instrument panels; and headliners. We are also one of the leading global suppliers of automotive electronic and electrical distribution systems. As a result of these capabilities, we can offer our customers fully-integrated modules, as well as design, engineering and project management support for the entire automotive interior, including electronics and electrical distribution systems.
We are focused on delivering high-quality automotive interior systems and components to our customers on a global basis. Due to the opportunity for substantial cost savings and improved product quality and consistency, automotive manufacturers have increasingly required their suppliers to manufacture automotive interior systems and components in multiple geographic markets. In recent years, we have followed our customers and expanded our operations significantly in Europe, South America, South Africa and the Asia/Pacific Rim region. As a result of our efforts to expand our worldwide operations, our sales outside the United States and Canada have grown from $2.2 billion in 1996 to $5.7 billion in 2001. In particular, our sales in Europe have grown from $1.6 billion in 1996 to $4.3 billion in 2001.
Strategy
Our principal objectives are to expand our position as a leading global
supplier of automotive interior systems and to continue to capitalize on
integration opportunities resulting from our electrical distribution system
capabilities. We intend to build on our full-service capabilities, strong
customer relationships and worldwide presence to increase our share of the
global automotive interior market. To this end, our strategy is to continue to
capitalize on four significant trends in the automotive industry:
| | the increasing emphasis on the automotive interior by automotive manufacturers as they seek to improve customer satisfaction and differentiate their vehicles in the marketplace; | ||
| | the increasing demand for fully-integrated modular assemblies, such as cockpits, overhead and door panel modules; | ||
| | the increasing consumer demand for added interior functionality to enhance and enable passenger convenience, on-board communication and safety; and | ||
| | the consolidation and globalization of the supply base of automotive manufacturers. |
The automotive manufacturers strategy is rooted in competitive pressures to improve quality and functionality at a lower cost and to reduce time to market, capital needs, labor costs, overhead and inventory. These trends have resulted in automotive manufacturers outsourcing complete modules of the interior as well as complete automotive interiors. Recently, we have received a number of business awards to design, engineer, manufacture, deliver and, in some cases, install complete interior modules as well as complete automotive interiors. We believe that the criteria for selection of automotive interior suppliers is not only cost, quality and responsiveness but increasingly includes worldwide presence and certain full-service capabilities.
Elements of our strategy include:
Enhance Strong Relationships with our Customers. We have developed strong relationships with our customers which allow us to identify business opportunities and anticipate customer needs in the early stages of vehicle design. We believe that working closely with our customers in the early stages of designing and engineering vehicle interior systems gives us a competitive advantage in securing new business. We work to maintain an excellent reputation with our customers for timely delivery and customer service and
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for providing world-class quality at competitive prices. In recognition of our efforts, many of our facilities have won awards from the automotive manufacturers.
Capitalize on Module and Integration Opportunities. We believe that the same competitive pressures that led automotive manufacturers to outsource the individual interior components to independent suppliers will cause our customers to demand delivery of fully-integrated modules for new vehicle models. As automotive manufacturers continue to seek ways to improve quality and reduce costs, we believe customers will increasingly look to independent suppliers to:
| | supply fully-integrated modules of the automotive interior; and | |
| | act as systems integrators, by managing the design, purchase and supply of the total automotive interior. |
Leverage Electronic Capabilities. Because electronic and electrical distribution systems and products are an increasingly important part of automotive interior systems, we have a competitive advantage in securing new business and taking advantage of integration opportunities as a result of our capabilities in this area.
Continue Global Expansion. Global expansion will continue to be an important element of our growth strategy. In 2001, approximately two-thirds of the global automotive interior production took place outside of North America. Our primary North American customers have made substantial investments in a number of international automakers, including General Motors acquisitions of or investments in Fiat, Saab, Daewoo Motor, Suzuki Motor and Isuzu Motor; Fords acquisitions of or investments in Jaguar, Volvo, Aston Martin, Land Rover and Mazda; and DaimlerChryslers investments in Mitsubishi Motors and Hyundai Motor. Furthermore, in recent years, automotive manufacturers in Europe have outsourced to a greater number of automotive suppliers than automotive manufacturers in North America. As a result, we have excellent opportunities for continued growth through the industrys global consolidation as automotive manufacturers reduce their supply bases to a leaner group of qualified suppliers with whom they do business. Markets such as South America and the Asia/Pacific Rim region also present long-term growth opportunities as demand for automotive vehicles increases and automotive manufacturers expand production in these markets. As a result of our strong customer relationships, worldwide presence and full-service capabilities, we are well-positioned to continue to grow with our customers as they expand their operations and consolidate their supplier base.
Increase Use of Just-in-Time Facility Network. We have established facilities that allow our customers to receive automotive interior products on a just-in-time basis. The just-in-time manufacturing process minimizes inventories and fixed costs for both us and our customers and enables us to deliver products on as little as ninety minutes notice. Most of our just-in-time manufacturing facilities are dedicated to individual customers. In many cases, by carefully managing floor space and overall efficiency, we can move the final assembly and sequencing of other automotive interior systems and components from centrally-located facilities to our existing just-in-time facilities. Combining our just-in-time manufacturing techniques with our systems integration capabilities provides us with an important competitive advantage in delivering total automotive interior systems to automotive manufacturers.
Maintain Flexible Cost Structure. We have one of the highest variable cost structures in the automotive supplier industry. By maintaining low fixed costs, we are better able to withstand fluctuations in industry demand as well as changing competitive and macroeconomic conditions. Our variable cost component is maintained, in part, through ongoing Six Sigma implementation throughout the organization, initiatives to promote and enhance the sharing of technology, engineering, purchasing and capital investment across customer platforms as well as restructuring initiatives to align our capacity with changing market conditions.
Invest in Product Technology and Design Capability. We will continue to make significant investments in technology and design capability to support our products. We maintain five advanced technology centers and several customer-focused product engineering centers where we design and develop new products and conduct extensive product testing. We also have state-of-the-art acoustics testing and instrumentation and data analysis capabilities.
We believe that in order to effectively develop total automotive interior systems, it is necessary to integrate the research, design, development, styling and validation of all of the automotive interior systems. Our advanced technology center provides us the ability to integrate engineering, research, development and validation capabilities for all five automotive interior systems at one location. Our investments in research and development are consumer driven and customer focused. We conduct extensive analysis and testing of consumer responses to automotive interior styling and innovations. Because automotive manufacturers increasingly view the vehicle interior as a major selling point to their customers, the focus of our research and development efforts is to identify new interior features that make vehicles safer, more comfortable and more attractive to consumers.
Products
We conduct our business in three product operating segments: seating; interior;
and electronic and electrical. The seating segment includes seat systems and
components thereof. The interior segment includes flooring and acoustic
systems, door panels, instrument panels, headliners and other interior
products. The electronic and electrical segment includes electronic and
electrical distribution systems, primarily wire harnesses, interior control
systems and wireless systems. Net sales for the year ended December 31, 2001
were comprised of the following: 68% seating; 18% interior and 14% electronic
and electrical.
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Seating. The seating business consists of the manufacture, assembly and supply of vehicle seating requirements. Seat systems typically represent approximately 30% to 40% of the cost of the total automotive interior. We produce seat systems for automobiles and light trucks that are fully finished and ready for installation. Seat systems are fully-assembled seats, designed to achieve maximum passenger comfort by adding a wide range of manual and power features such as lumbar supports, cushion and back bolsters and leg and thigh supports.
As a result of our product technology and product design strengths, we are a leader in incorporating convenience features and safety improvements into seat designs as well as in developing methods to reduce our customers costs throughout the automotive interior. For example, our Self-Aligning Head Restraint is an advancement in front seat passive safety. By reducing the space between the occupants head and the headrest in a rear impact situation through use of a headrest system that moves with the occupant, the difference between the rearward movement of the head and the shoulder area can be shortened, potentially reducing the risk of injury. In addition, we manufacture an integrated restraint seat system that increases occupant comfort and convenience. Exclusive to Lear, this patented seating concept uses an ultra high-strength steel tower and a split-frame design to improve occupant comfort and convenience. Finally, in the event of a crash, our Advanced Protection and Extrication System provides improved head protection as well as enhanced driver safety during the extrication and transport of an injured driver.
Interior. We have an extensive and comprehensive portfolio of SonoTecTM acoustic products, including flooring systems and dash insulators. Carpet flooring systems, used predominantly in passenger cars and trucks, generally consist of tufted carpet with a thermoplastic backcoating which, when heated, allows the carpet to be fitted precisely to the interior of the vehicle. Additional insulation materials are added to provide noise, vibration and harshness resistance. Wire harnesses are also included in the flooring system, allowing electronic modules located under the seats to be wired inexpensively. Vinyl flooring systems, used primarily in commercial and fleet vehicles, offer improved wear and maintenance characteristics. The dash insulator separates the passenger compartment from the engine compartment and is the primary component for preventing engine noise and heat from entering the passenger compartment.
Door panels consist of several component parts which are attached to a substrate by various methods. Specific components include vinyl or cloth-covered appliqués, armrests, radio speaker grilles, map pocket compartments, carpet and sound-reducing insulation. In addition, door panels often incorporate electronic and electrical distribution systems and products, including switches and wire harnesses for the control of power seats, windows, mirrors and door locks. Lears Flip PackTM switch combines seat and door controls into one assembly located on the door panel.
The instrument panel is a complex system of coverings, foams, plastics and metals designed to house various components and act as a safety device for the vehicle occupants. Specific components of the cockpit include the gauge cluster, the heating, ventilation and air conditioning module, air distribution ducts, air vents, cross car structure, glove compartment assemblies, electronic and electrical components, wiring harness, radio system and driver and passenger safety systems. One trend in the instrument panel segment relates to safety issues in air bag technologies. Through our research and development efforts, we intend to introduce cost-effective, integrated, seamless airbag covers which increase occupant safety. Future trends in the instrument panel segment will continue to focus on safety with the introduction of innovations such as knee restraints and energy-absorbing substructures.
Headliners consist of a substrate as well as a finished interior layer made of a variety of fabrics and materials. While headliners are an important contributor to interior aesthetics, they also provide insulation from road noise and can serve as carriers for a variety of other components, such as visors, overhead consoles, grab handles, coat hooks, electrical wiring, speakers, lighting and other electronic/electrical products. As electronic and electrical content available in vehicles has increased, headliners have emerged as an important carrier of technology since electronic features ranging from garage door openers to lighting systems are often optimally situated in the headliner system.
| | Electronic and Electrical. The electronic and electrical products are grouped into three categories: |
| Interior Control Systems. The instrument panel center console control provides a control panel for the entertainment system, accessory switch functions, heating, ventilation and air conditioning. The multifunction turn signal control consolidates various combinations of hazard lights, headlamps, parking lamps, fog lamps, wiper and washer, cruise control, high/low headlamp beams and turn signal functions. The integrated seat adjuster module combines seat adjustment, power lumbar support, memory function and heated seat into one package. Integrated door controls consolidate the controls for window lift, door lock, power mirror and heated seat. The integrated door and seat control flip panel system performs all power door and power seat functions from two stacked panels. | |
| Wireless Systems. The dual range/dual function remote keyless entry (RKE) system allows a single RKE transmitter button to perform multiple functions depending upon the operators distance from the vehicle. The remote keyless entry and immobilizer module combines the features of a remote keyless entry receiver and the immobilizer key reader into a single |
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| module. Custom key fobs use decorative molding technology to offer a wide variety of options in fob design patterns and colors including textures, logos, text and translucent and glow-in-the-dark colors. The passive entry system allows the vehicle operator to unlock the door without using a key or physically activating the RKE fob. The passive entry technology is imbedded in the fob so that a separate device is not required. |
| Electronic and Electrical Distribution Systems. Wire harness assemblies are a collection of terminals, connectors and wire that connect all the various electronic/electrical devices in the vehicle to each other and/or to a power source. Terminals and connectors are components of wire harnesses and other electronic/electrical devices that serve as a connection method between wire harnesses and electronic/electrical devices. Fuse boxes are centrally located boxes in the vehicle that contain fuses and/or relays for circuit and device protection as well as power distribution. Junction boxes serve as a connection point for multiple wire harnesses. They may also contain fuses and relays for circuit and device protection. |
The migration from electrical distribution systems to electronic and electrical distribution systems will facilitate the integration of wiring, electronics and switch / control products within the overall electrical architecture of a vehicle. IntertronicsTM, our unique ability to integrate electronic and electrical products into vehicle interior systems, is already having an impact. Our integrated seat adjuster module has two dozen fewer cut circuits and five fewer connectors, weighs a half of a pound less and costs 20% less than a traditional seat wiring system. Further, this migration can be seen in a number of new and next generation products. For example, our smart junction box combines traditional junction box function with electronic capabilities by incorporating electronic control functions traditionally located elsewhere in the vehicle.
In April 2001, we signed a Memorandum of Understanding with BERU Group of Ludwigsburg, Germany, a leading European sensor manufacturer, to jointly design and develop Tire Pressure Monitoring Systems (TPMS). TPMS will be required on all light vehicles sold in the U.S. by 2007, with phase-in requirements beginning in 2004. We are currently developing TPMS which combines our leading radio frequency electronics capabilities with BERUs sensor based technologies.
Manufacturing
A description of the manufacturing processes for each of our operating segments is set forth below.
Seating. Our seating facilities use just-in-time manufacturing techniques, and products are delivered to the automotive manufacturers on a just-in-time basis. Our seating facilities utilize a variety of methods whereby fabric is affixed to an underlying seat frame. Raw materials, including steel, aluminum and foam chemicals, used in our seat systems are obtained from several producers under various supply arrangements. These materials are readily available. Leather, fabric and certain purchased components are generally purchased from various suppliers under contractual arrangements usually lasting no longer than one year. Some of the purchased components are obtained from our customers.
Interior. The combined pressures of cost reduction and fuel economy enhancement have caused automotive manufacturers to concentrate their efforts on developing and employing lower-cost, lighter materials. As a result, plastic content in cars and light trucks has grown significantly. Increasingly, automotive content requires large plastic injection-molded assemblies for both the interior and exterior. Plastics are now commonly used in such nonstructural components as interior and exterior trim, door panels, instrument panels, grills, bumpers, duct systems, taillights and fluid reservoirs. We are continuing to develop recycling methods in an effort to meet current and future environmental conditions and requirements as well as to reduce costs.
Our interior trim systems process capabilities include injection molding, low-pressure injection molding, rotational molding, compression molding, urethane foaming and vacuum forming as well as various trimming and finishing methods. The principal purchased components for interior trim systems are polyethylene and polypropylene resins, which are generally purchased under long-term agreements and are available from multiple suppliers.
In addition, we produce carpet at our plant in Carlisle, Pennsylvania. Smaller facilities are dedicated to specific groups of customers and are strategically located near their production facilities.
Electronic and Electrical. Electrical distribution systems are networks of wiring and associated control devices that route electrical power and signals throughout the vehicle. Wire harness assemblies consist of raw, coiled wire which is automatically cut to length and terminated. Individual circuits are assembled together on a jig or table, inserted into connectors and wrapped or taped to form wire harness assemblies. Cell-based manufacturing techniques are applied to manufacture products on a just-in-time basis. Materials are purchased, with the exception of a portion of the connectors that are produced internally. The assembly process is labor intensive, and as a result, production is performed in low labor rate sites in Mexico, the Philippines, Europe and North Africa.
Some of the principal components attached to the wiring harness assemblies that we manufacture include junction boxes, electronic control modules and switches. Junction boxes are manufactured in North America and Europe with a proprietary, capital intensive
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assembly process utilizing printed circuit boards, purchased from selected suppliers. Electronic control modules are assembled using high-speed surface mount placement equipment in North America and Europe. Switches are assembled from electrical, mechanical and decorated plastic parts purchased in the United States, Mexico and Europe using a combination of manual and automated assembly and test methods.
Customers
We serve the worldwide automotive and light truck market, which produces over
55 million vehicles annually. We have automotive interior content on over 300
vehicle nameplates worldwide, and our automotive manufacturer customers
currently include:
| - | BMW | - | Daewoo | - | DaimlerChrysler | - | Fiat | |||
| - | Ford | - | Gaz | - | General Motors | - | Honda | |||
| - | Hyundai | - | Isuzu | - | Jaguar | - | Mahindra & Mahindra | |||
| - | Mazda | - | Mitsubishi | - | Nissan | - | Peugeot | |||
| - | Porsche | - | Renault | - | Saab | - | Subaru | |||
| - | Suzuki | - | Toyota | - | Volkswagen | - | Volvo |
During the year ended December 31, 2001, General Motors and Ford, the two largest automotive and light truck manufacturers in the world, including their affiliates, accounted for approximately 33% and 27%, respectively, of our net sales. For additional information regarding customers and domestic and foreign sales and operations, see Note 13, Segment Reporting, to the consolidated financial statements included in this Report.
We receive blanket purchase orders from our customers that normally cover annual requirements for products to be supplied for a particular vehicle model. Such supply relationships typically extend over the life of the model, with terms up to ten years, and do not require the customer to purchase a minimum number of products. Although purchase orders may be terminated at any time, such terminations are rare and have not had a material impact on our results of operations. Our primary risk is that an automotive manufacturer will produce fewer units of a model than anticipated. In order to reduce our reliance on any one model, we produce automotive interior systems and components for a broad cross-section of both new and more established models. Our sales for the year ended December 31, 2001 were comprised of the following vehicle categories: 45% light truck; 25% mid-size; 12% luxury/sport; 15% compact; and 3% full-size.
Our contracts with our major customers generally provide for an annual productivity price reduction and provide for the recovery of increases in material and labor costs in some instances. Historically, cost reductions through product design changes, increased productivity and similar programs with our suppliers have generally offset changes in selling prices, although no assurances can be given that we will be able to achieve such cost reductions in the future. Our cost structure is comprised of a high percentage of variable costs. This structure provides us with additional flexibility during various economic cycles.
Technology
Advanced technology development is conducted at our advanced technology center
in Southfield, Michigan, under the group name VisionWorks, and at several
worldwide product engineering centers. At these centers, we engineer our
products to comply with applicable safety standards, meet quality and
durability standards, respond to environmental conditions and conform to
customer requirements.
We also have state-of-the-art acoustics testing and instrumentation and data analysis capabilities. We own one of the few proprietary-design acoustical testing chambers with an integrated four-wheel dynamometer capable of precision acoustics testing of front, rear and four-wheel drive vehicles. Together with our custom-designed reverberation room, computer-controlled data acquisition and analysis capabilities provide precisely controlled laboratory testing conditions for sophisticated interior and exterior noise, vibration and harshness testing of parts, materials and systems, including powertrain, exhaust and suspension components.
We have developed a number of designs for innovative interior features which we have patented, all focused on increasing value to the customer. Examples include our proprietary Common Architecture Strategy, allowing freedom of choice and configuration of interior components at mass production prices, the TransG aging baby-boomer vehicle interior, the OASys overhead audio system, the Revolution Seating system and the One-Step door and One-Step liftgate modules. In 2000, we introduced Intertronics, a capability that shows tremendous potential to integrate electronic products with vehicle interior systems. Intertronics products and technologies are grouped into three categories: Interior Control Systems, Wireless Systems and Electronic and Electrical Distribution Systems, which includes smart junction boxes, advanced electronic products and switches and remote keyless entry systems. In May 2000, we opened the Intertronics Innovation Center at our electronic and electrical facility in Dearborn to demonstrate our commitment to growing this business. In addition, we incorporate many convenience, comfort and safety features into our interior designs,
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including advanced whiplash concepts, lifestyle vehicle interior storage systems, overhead integrated modules, seat integrated restraint systems (3-point and 4-point belt systems integrated into seats), side impact air bags, child restraint seats and integrated instrument panel air-bag systems. We continually invest in our computer-aided-engineering-design and computer-aided-manufacturing systems. Recent enhancements to these systems include advanced acoustic modeling and analysis capabilities and the enhancement of our Virtual Technology Division (VTD) web site allowing customer telecommunications and the direct exchange of engineering data and information with other worldwide divisions.
We have created brand identities, which highlight products for our customers. The ProTec brand identifies products optimized for interior safety; the SonoTec brand identifies products optimized for interior acoustics; and the EnviroTec brand identifies environmentally friendly products.
We hold in excess of 2,500 patents worldwide covering our products and have numerous applications for patents currently pending. In addition, we hold several trademarks relating to various manufacturing processes. We also license selected technologies to automotive manufacturers and other seating manufacturers. We continually strive to identify and implement new technologies for use in the design and development of our products.
We have dedicated, and will continue to dedicate, resources to research and development in order to maintain our position as a leading developer of technology in the automotive interior industry. Research and development costs incurred in connection with the development of new products and manufacturing methods, to the extent not recoverable from the customer, are charged to selling, general and administrative expenses as incurred. Such costs amounted to approximately $198.6 million, $208.7 million and $181.2 million for the years ended December 31, 2001, 2000 and 1999, respectively.
Joint Ventures and Minority
Interests
We pursue attractive joint ventures in order to assist our entry into new
markets, facilitate the exchange of technical information, expand our product
offerings and broaden our customer base. We currently have thirty-four joint
ventures located in fifteen countries. Fourteen of these joint ventures are
consolidated, sixteen are accounted for using the equity method of accounting
and four are accounted for using the cost method of accounting. Net sales of
our consolidated joint ventures accounted for less than 3% of our net sales for
the year ended December 31, 2001. Our investments in unconsolidated joint
ventures totaled $53.8 million as of December 31, 2001. See Note 6,
Investments in Affiliates, to the consolidated financial statements included
in this Report for additional information on our joint ventures.
Competition
Within each of our operating segments, we compete with a variety of independent
suppliers and automotive manufacturer in-house operations, primarily on the
basis of cost, product quality and service. Set forth below is a summary of
our primary independent competitors.
Seating. We are one of two primary independent suppliers in the outsourced North American seat systems market. Our primary independent competitor in this market is Johnson Controls. Our major independent competitors in Western Europe are Johnson Controls and Faurecia (headquartered in France).
Interior. We are one of the three primary independent suppliers in the outsourced North American flooring and acoustic systems market as well as one of the largest global suppliers of door panels, instrument panels and headliners. Our primary independent competitors in the flooring and acoustic systems market are Collins & Aikman and Rieter Automotive. Our major independent competitors in the outsourced Western European flooring and acoustic systems market include Faurecia, Intier, Radici, Borgers, Rieter Automotive and Treves. Our major independent competitors in the remaining interior markets include Johnson Controls, Intier, Collins & Aikman, Delphi, Visteon, Faurecia and a large number of smaller operations.
Electronic and Electrical. We are one of the leading independent suppliers of automotive electrical distribution systems in North America and Western Europe. Our major competitors in this market include Delphi, Yazaki and Sumitomo. The automotive electronic/electrical products industry remains highly fragmented. Other participants include Tokai Rika, Kostal, Methode, Cherry, Niles, Omron, Delphi, TRW, Alps, Valeo, Siemens VDO, Bosch, Denso and others.
Seasonality
Our principal operations are directly related to the automotive industry.
Consequently, we may experience seasonal fluctuations to the extent automotive
vehicle production slows, such as in the summer months when plants close for
model year changeovers and vacations. Historically, our sales and operating
profit have been the strongest in the second and fourth calendar quarters. See
Note 15, Quarterly Financial Data, to the consolidated financial statements
included in this Report.
Our cost structure is comprised of a high percentage of variable costs. This structure provides us with additional flexibility during various economic cycles.
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Employees
As of December 31, 2001, Lear employed approximately 35,000 people in the
United States and Canada, 34,000 in Mexico, 35,000 in Europe and 12,000 in
other regions of the world. A substantial number of our employees are members
of unions. We have collective bargaining agreements with several unions
including: the UAW; the CAW; UNITE; the International Brotherhood of Teamsters,
Chauffeurs, Warehousemen and Helpers of America; and the International
Association of Machinists and Aerospace Workers. Virtually all of our
unionized facilities in the United States and Canada have a separate contract
with the union that represents the workers employed there. Each such contract
has an expiration date independent of our other labor contracts. The majority
of our European and Mexican employees are members of industrial trade union
organizations and confederations within their respective countries. Many of
these organizations and confederations operate under national contracts, which
are not specific to any one employer. We have occasionally experienced labor
disputes at our plants, none of which has significantly disrupted production or
had a material adverse effect on our operations. We have been able to resolve
all such labor disputes and believe our relations with our employees are
generally good.
See Managements Discussion and Analysis of Financial Condition and Results of Operations Forward-Looking Statements and Risk Factors.
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ITEM 2 PROPERTIES
As of December 31, 2001, our operations were conducted through 309 facilities, some of which are used for multiple purposes, including 160 production/manufacturing sites, 53 JIT sites, 39 administrative/technical support sites, 9 assembly sites, 5 advanced technology centers and 5 distribution centers, in 33 countries. The remaining facilities are primarily warehouses. Our world headquarters is located in Southfield, Michigan. Our facilities range in size up to 1,016,000 square feet.
Of the 309 facilities, which include facilities owned by our less than majority-owned affiliates, 159 are owned and 150 are leased with expiration dates ranging from 2001 through 2021. We believe substantially all of our property and equipment is in good condition and that we have sufficient capacity to meet our current and expected manufacturing and distribution needs. See Managements Discussion and Analysis of Financial Condition and Results of Operations Liquidity and Financial Condition Cash Flow.
The following table presents the locations of our facilities:
| Argentina | France | Italy | Singapore | United States | United States | |||||
| Escobar, BA | Cergy | Bellizzi, SA | Singapore | Allen Park, MI | (Continued) | |||||
| Ferreyra, CO | Compans | Caivano, NA | Alma, MI | Oklahoma City, OK | ||||||
| Pacheco, BA | Garches | Cassino, FR | Slovakia | Arlington, TX | Peru, IN | |||||
| San Luis, SL | Guipry | Grugliasco, TO | Bratislava | Atlanta, GA | Plymouth, IN | |||||
| Lagny-le-sec | Melfi, PZ | Auburn Hills, MI | Plymouth, MI | |||||||
| Austria | Meaux | Montelabbate, PS | South Africa | Berne, IN | Pontiac, MI | |||||
| Graz | Offranville | Orbassano, TO | Brits | Bourbon, IN | Port Huron, MI | |||||
| Koeflach | Pianfei, CN | East London | Bowling Green, OH | Riverside, IA | ||||||
| Germany | Pozzo dAdda, MI | Port Elizabeth | Bridgeton, MO | Rochester Hills, MI | ||||||
| Belgium | Besigheim | Termini Imerese, PA | Rosslynn | Carlisle, PA | Romulus, MI | |||||
| Genk | Boblingen | Villastellone, TO | Woodbrook | Columbus, OH | Roscommon, MI | |||||
| Bremen | Covington, VA | Sheboygan, WI | ||||||||
| Brazil | Ebersberg | Japan | South Korea | Dayton, TN | Sidney, OH | |||||
| Betim | Eisenach | Atsugi | Seoul | Dearborn, MI | Southfield, MI | |||||
| Cacapava | Enseldorf | Hiroshima | Detroit, MI | Strasburg, VA | ||||||
| Camacari | Gaimersheim | Tokyo | Spain | Delphi Twp. MI | Tampa, FL | |||||
| Curitiba | Garching-Hochbruck | Toyota City | Almussafes, VA | Duncan, SC | Taylor, MI | |||||
| Diadema | Ginsheim-Gustavsburg | Avila, AV | Edinburgh, IN | Traverse City, MI | ||||||
| Gravatai | Koln | Mexico | Cevera, LE | El Paso, TX | Troy, MI | |||||
| Juiz de For a | Kronach | Chihuahua, CH | Epila, ZA | Elsie, MI | Walker, MI | |||||
| Sao Paulo | Munchen | Cuautitlan | Logrono, LR | Evansville, IN | Warren, MI | |||||
| Plattling | Izcalli, MX | Roquetes, TA | Fenton, MI | Warren, OH | ||||||
| Canada | Quakenbruck | Hermosillo, SO | Valdermoro, MD | Frankfort, IN | Wauseon, OH | |||||
| Ajax | Rietberg | Juarez, CH | Valls, TA | Fremont, OH | Wentzville, MO | |||||
| Concord | Saarlouis | Leon, GO | Grand Rapids, MI | Winchester, VA | ||||||
| Kitchener | Sulzbach | Mexico City, DF | Sweden | Greencastle, IN | Zanesville, OH | |||||
| Mississauga | Wackersdorf | Naucalpan, MX | Fargelanda | Greensboro, NC | ||||||
| Oakville | Wolfsburg | Puebla, PU | Gothenburg | Hammond, IN | Venezuela | |||||
| St. Thomas | Zwiesel | Ramos Arizpe, CO | Tanumshede | Highland Park, MI | Valencia | |||||
| Whitby | Saltillo, CO | Tidaholm | Holland, MI | |||||||
| Windsor | Honduras | Santa Catarina, NL | Trollhattan | Hunington, IN | ||||||
| Woodstock | Naco, SB | Toluca, MX | Huron, OH | |||||||
| Thailand | Iowa City, IA | |||||||||
| China | Hungary | Netherlands | Bangkok | Ithaca, MI | ||||||
| Chongqing | Godollo | Weesp | Nakornratchasima | Janesville, WI | ||||||
| Hong Kong | Gyoer | Rayong | Lebanon, OH | |||||||
| Nanchang | Gyonygos | Philippines | Lebanon, VA | |||||||
| Shanghai | Mor | Lapu-Lapu City, | Tunisia | Lewistown, PA | ||||||
| Wuhan | Cebu | Bir El Bey | Lexington, KY | |||||||
| India | Liberty, MO | |||||||||
| Czech Republic | Chennai | Poland | Turkey | Louisville, KY | ||||||
| Prestice | Halol | Bielsko-Biala | Bursa | Madison Heights, MI | ||||||
| Nasik | Mielec | Kocaeli | Madisonville, KY | |||||||
| England | New Delhi | Plock | Manteca, CA | |||||||
| Basildon, SS | Thane | Swidnica | Marlette, MI | |||||||
| Bicester, OX | Tychy | Marshall, MI | ||||||||
| Coventry, CV | Mason, MI | |||||||||
| Coventry, M | Portugal | Melvindale, MI | ||||||||
| Kenilworth, WA | Palmela, SL | Mendon, MI | ||||||||
| Liverpool, ME | Povoa de Lanhoso, | Morristown, TN | ||||||||
| Nottingham, NG | BA | New Castle, DE | ||||||||
| Shepperton, SU | Valongo, PO | Newark, DE | ||||||||
| Tamworth, ST | Northwood, OH | |||||||||
| Tipton, M | Romania | Novi, MI | ||||||||
| Washington, TY | Pitesti | OFallon, MO | ||||||||
| Russia | ||||||||||
| Nihzny Novgorod |
8
ITEM 3 LEGAL PROCEEDINGS
We are involved in certain legal actions and claims arising in the ordinary course of business. We do not believe that any of the litigation in which we are currently engaged, either individually or in the aggregate, will have a material adverse effect on our business, consolidated financial position or results of future operations.
We are subject to local, state, federal and foreign laws, regulations and ordinances, which govern activities or operations that may have adverse environmental effects and which impose liability for the costs of cleaning up certain damages resulting from past spills, disposal or other releases of hazardous wastes and environmental compliance. Our policy is to comply with all applicable environmental laws and to maintain procedures to ensure compliance. However, we have been, and in the future may become, the subject of formal or informal enforcement actions or procedures. See Managements Discussion and Analysis of Financial Condition and Results of Operations Environmental Matters.
We have been named as a potentially responsible party at several third party landfill sites and are engaged in the cleanup of hazardous wastes at certain sites owned, leased or operated by us, including several properties acquired in the UT Automotive acquisition. Certain present and former properties of UT Automotive are subject to environmental liabilities which may be significant. We obtained agreements and indemnities with respect to possible environmental liabilities from United Technologies Corporation in connection with our acquisition of UT Automotive. While we do not believe that the environmental liabilities associated with our properties will have a material adverse effect on our business, consolidated financial position or results of future operations, no assurances can be given in this regard.
ITEM 4 SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS
No matters were submitted to a vote of security holders during the fourth quarter of 2001.
9
PART II
ITEM 5 MARKET FOR THE COMPANYS COMMON STOCK AND RELATED
STOCKHOLDER MATTERS
Lears Common Stock is listed on the New York Stock Exchange under the symbol LEA. The Transfer Agent and Registrar for Lears Common Stock is The Bank of New York, located in New York, New York. On March 1, 2002, there were 1,087 holders of record of Lears Common Stock.
To date, we have never paid a cash dividend on our Common Stock. Any payment of dividends in the future is dependent upon our financial condition, capital requirements, earnings and other factors. Also, we are subject to the restrictions on the payment of dividends contained in our primary credit facilities and in certain other contractual obligations. See Note 8, Long-Term Debt, to the consolidated financial statements included in this Report.
In February 2002, we issued $640 million aggregate principal amount at maturity of zero-coupon convertible senior notes due 2022 in a private offering, yielding gross proceeds of $250 million. Each $1,000 principal amount of notes at maturity is convertible into 7.5204 shares of our common stock, subject to adjustment, under certain circumstances. See Managements Discussion and Analysis of Financial Condition and Results of Operations Liquidity and Financial Condition and Note 8, Long-Term Debt, to the consolidated financial statements included in this Report.
The following table sets forth the high and low sales prices per share of Common Stock, as reported by the New York Stock Exchange, for the periods indicated:
| Price Range of | ||||||||
| Year Ended December 31, 2001: | Common Stock | |||||||
| High | Low | |||||||
4th Quarter |
$ | 38.20 | $ | 26.52 | ||||
3rd Quarter |
$ | 42.14 | $ | 24.42 | ||||
2nd Quarter |
$ | 38.50 | $ | 28.40 | ||||
1st Quarter |
$ | 34.70 | $ | 24.50 | ||||
| Price Range of | ||||||||
| Year Ended December 31, 2000: | Common Stock | |||||||
| High | Low | |||||||
4th Quarter |
$ | 27.25 | $ | 20.19 | ||||
3rd Quarter |
$ | 26.56 | $ | 19.94 | ||||
2nd Quarter |
$ | 30.19 | $ | 19.98 | ||||
1st Quarter |
$ | 35.44 | $ | 19.94 | ||||
10
ITEM 6 SELECTED FINANCIAL DATA
The following income statement and balance sheet data were derived from our consolidated financial statements. Our consolidated financial statements for the years ended December 31, 2001, 2000, 1999, 1998 and 1997, have been audited by Arthur Andersen LLP. The selected financial data below should be read in conjunction with our consolidated financial statements and the notes thereto and Managements Discussion and Analysis of Financial Condition and Results of Operations included in this Report.
| For the year ended December 31, | 2001(1) | 2000(2) | 1999(3) | 1998(4) | 1997 | ||||||||||||||||
| (In millions (5)) | |||||||||||||||||||||
Operating Data: |
|||||||||||||||||||||
Net sales |
$ | 13,624.7 | $ | 14,072.8 | $ | 12,428.8 | $ | 9,059.4 | $ | 7,342.9 | |||||||||||