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UNITED STATES SECURITIES AND EXCHANGE COMMISSION
Washington, DC 20549
Form 10-K
FOR ANNUAL AND TRANSITION REPORTS
PURSUANT TO SECTIONS 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934
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ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
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For the fiscal year ended December 31, 2004 |
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TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
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For the transition period
from to |
Commission file number: 333-107219
United Components, Inc.
(Exact Name of Registrant as Specified in Its Charter)
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Delaware
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04-3759857 |
(State or Other Jurisdiction of
Incorporation or Organization) |
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(I.R.S. Employer
Identification No.) |
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14601 Highway 41 North
Evansville, Indiana
(Address of Principal Executive Offices) |
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47725
(Zip Code) |
Registrants telephone number, including area code:
(812) 867-4156
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 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 o No þ
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. þ
Indicate by check mark whether the registrant is an accelerated
filer (as defined in Exchange Act
Rule 12b-2). Yes o No þ
Documents Incorporated by Reference: None
TABLE OF CONTENTS
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Page | |
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Part I |
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Item 1.
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Business |
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2 |
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Item 2.
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Properties |
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14 |
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Item 3.
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Legal Proceedings |
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15 |
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Item 4.
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Submission of Matters to a Vote of Security Holders |
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15 |
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Part II |
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Item 5.
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Market for Registrants Common Equity and Related
Stockholder Matters |
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15 |
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Item 6.
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Selected Financial Data |
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16 |
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Item 7.
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Managements Discussion and Analysis of Financial Condition
and Results of Operations |
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Item 7A.
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Quantitative and Qualitative Disclosures About Market Risk |
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28 |
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Item 8.
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Financial Statements and Supplementary Data |
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29 |
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Item 9.
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Changes in and Disagreements with Accountants on Accounting and
Financial Disclosure |
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71 |
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Item 9A.
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Controls and Procedures |
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71 |
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Item 9B.
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Other Information |
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71 |
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Part III |
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Item 10.
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Directors and Executive Officers of the Registrant |
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71 |
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Item 11.
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Executive Compensation |
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73 |
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Item 12.
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Security Ownership of Certain Beneficial Owners and Management
and Related Stockholder Matters |
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76 |
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Item 13.
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Certain Relationships and Related Transactions |
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77 |
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Item 14.
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Principal Accountant Fees and Services |
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78 |
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Part IV |
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Item 15.
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Exhibits and Financial Statement Schedules |
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78 |
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Signatures |
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84 |
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1
PART I
Overview
United Components, Inc. (UCI, the
Company, or we) was incorporated on
April 16, 2003, and on June 20, 2003, we purchased all
of our operating units from UIS, Inc., and UIS Industries, Inc.
(together UIS). For more information regarding the
purchase of our operations, see The Acquisition and
Ownership section, which immediately follows this overview.
Prior to June 20, 2003, our operations comprised the
vehicle parts businesses of UIS. Beginning with the purchase of
Airtex in 1958, UIS continued acquisitions in the automotive
industry over the following four decades, resulting in the
acquisitions of Wells Manufacturing, Champion Laboratories,
Neapco, Flexible Lamps and Pioneer. Over the years, UIS achieved
growth in these businesses through increased parts offerings and
domestic and international expansion.
We are among North Americas largest and most diversified
companies servicing the vehicle replacement parts market, or the
aftermarket. We supply a broad range of filtration products,
fuel and cooling systems, engine management components,
driveline components and lighting systems to the automotive,
trucking, marine, mining, construction, agricultural and
industrial vehicle markets. We estimate that about 77% of our
net sales in 2004 were made in the aftermarket, to a customer
base that includes some of the largest and fastest growing
companies servicing the aftermarket. We continue to expand our
product and service offerings to meet the changing needs of our
customers, and we believe that we offer one of the most
comprehensive lines of products in the vehicle replacement parts
market consisting of over 60,000 parts. We believe our
breadth of product offering, in combination with our extensive
manufacturing and distribution capabilities, product innovation
and reputation for quality and service, are responsible for our
ongoing leadership position in our industry. We have established
a network of manufacturing facilities, distribution centers and
offices located in the United States, Europe, Mexico and China,
with a global work force of approximately 6,900 employees as of
December 31, 2004. In 2004, our net sales were
$1,026.7 million.
Unlike many companies that are exclusively or primarily original
equipment suppliers, our sales do not necessarily correlate to
annual vehicle production. Rather, we believe that the majority
of our sales tend to track more closely with the overall growth
of the aftermarket. We believe that the aftermarket will
continue to grow as a result of increases in the median age of
vehicles, total number of miles driven per year by passenger
cars, number of vehicles registered in the United States, number
of licensed drivers and number of light trucks and sport utility
vehicles, which generally require higher priced replacement
parts.
We believe our primary product lines are well positioned in the
aftermarket, as our filtration products have relatively short
and predictable replacement cycles and our fuel and cooling
systems and engine management systems are non-discretionary
replacement items. The need for our products increases as cars
reach the prime age (six years or older) for aftermarket
maintenance. We believe our diversity across products and sales
channels is also among the most attractive in the industry, and
this diversity allows us to benefit from positive trends
impacting different products and sales channels. We have also
developed longstanding relationships with our customers through
our breadth of product offering, emphasis on customer service,
product quality and competitive pricing, as evidenced by the
customer awards we have earned over the years. Our customer base
includes leading aftermarket companies such as Advance Stores
Company, Inc. (Advance Auto Parts), Valvoline Company, a
division of Ashland Inc. (Valvoline), AutoZone, Inc. (AutoZone),
Carquest Corporation (CARQUEST), MDSA, Inc. (Mighty) and
National Automotive Parts Association, a wholly-owned subsidiary
of Genuine Parts Company (NAPA), as well as a diverse group of
original equipment manufacturers, or OEMs, such as
DaimlerChrysler Corporation (DaimlerChrysler), CNH Global N.V.
(Case New Holland), Ford Motor Company, Inc. (Ford), General
Motors Corporation (GM), Harley-Davidson, Inc.
(Harley-Davidson), Deere & Company (John Deere),
Mercury Marine Division of Brunswick Corporation (Mercury
Marine), Polaris Industries, Inc. (Polaris), Volkswagen of
America, Inc. (Volkswagen) and Volvo Truck Corporation (Volvo).
2
The Acquisition and Ownership
On June 20, 2003, we purchased the vehicle parts businesses
of UIS, consisting of all of the issued and outstanding common
stock or other equity interests of Champion Laboratories, Inc.,
Wells Manufacturing Corporation, Neapco Inc., Pioneer, Inc.,
Wells Manufacturing Canada Limited, UIS Industries Ltd. (which
is the owner of 100% of the capital stock of Flexible Lamps,
Ltd. and Airtex Products Ltd.), Airtex Products S.A., Airtex
Products, Inc., (currently Airtex Mfg., Inc.), Talleres
Mecanicos Montserrat S.A. de C.V., Brummer Seal de Mexico, S.A.
de C.V., Brummer Mexicana en Puebla, S. A. de C.V., Automotive
Accessory Co. Ltd and Airtex Products, LLC, predecessors to the
entities that now own the assets of the Airtex business. We
refer to this transaction as the Acquisition.
The purchase price paid was $808 million, plus transaction
fees. The Acquisition was financed through a combination of debt
and $260 million in cash contributed to us as equity by our
parent, UCI Acquisition Holdings, Inc. through contributions
from Carlyle Partners III, L.P. and CP III
Coinvestment, L.P. We are a wholly owned subsidiary of UCI
Acquisition Holdings, Inc. We and UCI Acquisition Holdings, Inc.
are corporations formed at the direction of The Carlyle Group,
which we refer to as Carlyle.
Our Industry
The North American vehicle parts industry contains numerous
participants, few with our diverse product lines. We believe
industry participants are increasingly focused on reducing the
size of their supply base and, therefore, value suppliers with a
diverse offering of quality products, customized service, and
consistent and timely delivery of products. Our industry is also
characterized by relatively high barriers to entry, which
include the need for significant start-up capital expenditures,
initial product depth within a product line, distribution
infrastructure and long-standing customer relationships.
The vehicle parts industry is comprised of four main sales
channels: the retail sales channel, the traditional sales
channel, the original equipment service (OES) sales
channel, and the original equipment manufacturer
(OEM) sales channel. The retail, traditional and OES sales
channels together comprise the aftermarket. The characteristics
of the aftermarket vary considerably from that of the OEM sales
channel. While product sales for use by OEMs are one-time sales
events, product sales in the aftermarket are of replacement
products that are repeatedly purchased. Historically, the
largest portion of our net sales has been to the aftermarket
portion of the vehicle parts industry. According to the
2004/2005 AAIA Aftermarket Factbook, the U.S. automotive
aftermarket (excluding tires) is large and fragmented with an
estimated $165 billion of aggregate retail sales in 2003
and is organized around two groups of end-users: the
do-it-yourself group (DIY), and the do-it-for-me group (DIFM).
The DIY group, which is supplied primarily through the retail
channel (e.g., Advance Auto Parts, AutoZone, Pep Boys and
Wal-Mart), represented an estimated 21% of industry-wide
aftermarket sales in 2003 and consists of consumers who prefer
to do various repairs on their vehicles themselves. The DIFM
group is supplied primarily through the traditional channel
(e.g., CARQUEST and NAPA), which represented an estimated 79% of
industry-wide aftermarket sales in 2003, and consists of car
dealers, repair shops, service stations and independent
installers who perform the work for the consumer.
According to the 2004/2005 AAIA Aftermarket Factbook, the
automotive aftermarket (excluding tires) has grown at an annual
average rate of approximately 3.7% from 1994 through 2003. There
are a number of factors that contribute to this growth of
aftermarket sales, including:
Consumers are retaining their cars longer. According to
R.L. Polk and Co., the median age for passenger cars has
increased 82% from 4.9 years in 1970 to 8.9 years in
2004. Because of the significant increase in new car sales in
the late 1990s, we believe a surge of vehicles entering the
prime age for aftermarket maintenance began in 2004.
Increasing number of miles driven. The demand for the
majority of our products is tied to the regular replacement
cycle or the natural wearing cycle of a vehicle part based on
actual miles driven. According to the 2004 AASA Automotive
Aftermarket Status Report prepared by MEMA (Motor and Equipment
Manufacturers Association), annual miles driven in the United
States by all types of wheeled vehicles increased every year
between 1970 and 2001 with the exception of the three years
coinciding with the oil crises of 1974, 1979 and 1980. The
2004/2005 AAIA Aftermarket Factbook reports that from 1993 to
2002, the total miles driven
3
for passenger cars and light trucks increased by 23%, with a
compound annual growth rate of 2%. We believe this trend is
likely to continue.
Increasing number of registrations. According to R.L.
Polk and Co., the number of registered passenger cars and light
trucks, or light vehicles, has increased by 23% since 1993. The
2004 Wards Motor Vehicle Facts & Figures book
reports that the number of licensed drivers has grown by 12%.
According to the 2004/2005 AAIA Aftermarket Factbook, the
U.S. light vehicle market achieved the highest total sales
on record with 17.4 million cars and light trucks sold in
2000. We believe the buildup in vehicle sales volumes between
1999 and 2002 will also drive the growth in the installed base
of older vehicles over the next several years.
Shifting vehicle mix. The number of light vehicles in use
has increased over the past ten years, primarily due to growing
consumer interest in pickup trucks and sport utility vehicles,
or SUVs. From 1994 to 2003, the number of light trucks in use
grew annually by 3.6%, compared to a 0.7% annual increase in
passenger cars in use during the same period. By 2002, light
trucks began outselling passenger cars. In 2003, light trucks
accounted for 53% of all new light vehicle sales. In 2003, 58%
of total light vehicles in operation were passenger cars, down
from 65% in 1994. This trend is significant as light truck parts
are generally more expensive than the parts for passenger cars.
Our Competitive Strengths
Market Leadership. We are among North Americas
largest companies serving the aftermarket, supplying a broad
range of vehicle replacement products. We have served our market
for many years and, as a result of our performance record, we
have won a number of awards from our customers. We believe we
are among the market leaders in several of our key business
lines, including filtration products, fuel and cooling systems,
engine management components, and driveline components.
Breadth of Product Offering and Service. We believe our
product portfolio is one of the broadest in the North American
vehicle parts industry. We currently offer over 60,000 parts,
which provide our business with a competitive advantage by
enabling us to offer our customers a wide array of quality
products. In addition, we believe we have an excellent
reputation with our customers for providing high quality
components, as well as timely delivery, high unit fill rates and
customer service.
Diversified Businesses. We believe the diversity across
our products and sales channels is among the most attractive in
the industry. Our diversification enables us to capitalize on
the growth of the traditional channel, align ourselves with
rapidly growing retailers, enhance our recognition in the
aftermarket through original equipment sales, and increase our
ability to pursue sales in other growth areas, including the
heavy-duty filtration market. We also believe our
diversification, combined with the non-discretionary replacement
nature of our products, lessens the impact of an economic
downturn on our business. The following table describes our
approximate 2004 net sales by percentage of product and
percentage of sales channel:
2004 Net Sales
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By Sales Channel | |
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Oil Filters
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20 |
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Retail |
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29 |
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Air Filters
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7 |
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Traditional |
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20 |
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Fuel Filters
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5 |
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Heavy-duty Traditional |
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10 |
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Other Filters(1)
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4 |
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Installer |
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8 |
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Fuel Pumps and Assemblies
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20 |
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OES |
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10 |
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Cooling Systems
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13 |
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Auto OEM |
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10 |
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Engine, Driveline and Lighting
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RV OEM |
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2 |
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Systems(2)
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31 |
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Truck/Trailer OEM |
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5 |
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Other |
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6 |
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Total Net Sales
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100 |
% |
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Total Net Sales |
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100 |
% |
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Other Filters includes cabin air filters, hydraulic filters,
transmission filters, PVC valves and industrial filters. |
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Engine, Driveline and Lighting Systems primarily includes
ignition products, signal lighting equipment, specialty
distribution, engine management systems, universal joints,
electronic controls and heavy-duty components. |
Experienced Management Team. Our operations are led by an
experienced management team with an average of almost
20 years of industry experience. In addition, David Squier,
the former Chief Executive Officer of Howmet Corporation, is our
Chairman of the Board and Bruce Zorich, the former Chief
Executive Officer of Magnatrax Corporation and former President
of Huck International, Inc., is our Chief Executive Officer.
Both of these individuals have experience with implementing lean
manufacturing methodologies to realize cost savings and improve
cash flow.
Our Strategy
Our strategic objective is to maximize our return on invested
capital by using our strong market position, our breadth of
product offering and our strong customer relationships to take
advantage of the increasing demand for vehicle replacement parts.
Focus on Operating Efficiency. We have pursued, and will
continue to pursue, opportunities to optimize our resources and
reduce manufacturing costs by, among other things, executing
strategic initiatives aimed at improving our operating
performance and lowering our manufacturing costs. In 2004, we
continued our implementation of a capital investment plan at our
filtration production operations, which is designed to expand
capacity and reduce manufacturing costs by focusing on lean
manufacturing techniques and automation. The first phase of this
project, which was completed during the third quarter of 2003,
has already begun to lower our cost structure. The second phase
is scheduled to be completed in the first half of 2005 and will
consolidate the operations at two facilities and add new,
high-speed assembly lines for our filtration manufacturing
processes. We believe these investments will significantly
reduce the labor content involved in assembly, generate a
substantial amount of annual cost savings, and add significant
production capacity.
Another of our strategic initiatives is the consolidation of the
manufacturing operations in our fuel and cooling systems
business. This initiative, scheduled to be completed in the
first half of 2005, will reduce the number of manufacturing
facilities in this business from five to two. This consolidation
is the result of our focus on lean manufacturing techniques and
creating available manufacturing space through inventory
reduction.
As of the beginning of 2005, we have completed the consolidation
of our distribution network from 25 facilities to 12. This
consolidation simplifies our product flow from manufacture to
customer and will help reduce the amount of duplicate inventory
historically stored in multiple locations.
Our final strategic operating initiative is the centralization
of our procurement activities. Through this initiative we have
begun to utilize best practices throughout our purchasing
activity and we will be able to leverage the buying power of the
Company as a whole. We are also reducing the number of suppliers
we use and have increased the percentage of our purchases from
foreign sources. These activities achieved positive results in
our cost of sales in 2004 and we expect to achieve additional
positive results in 2005.
Capitalize on Favorable Aftermarket Trends. Several
trends are likely to affect growth and profitability positively
in the aftermarket, including increases in the median age of
vehicles, total annual number of light vehicle miles driven,
number of vehicles registered in the United States, number of
licensed drivers and number of light trucks and sport utility
vehicles, which generally require higher priced replacement
parts. Because of our breadth and depth of product offerings,
diversity of sales channels served and leading market positions,
we believe we are well positioned to benefit from this growth in
the aftermarket. As such, we are focused on expanding our
product lines and solidifying our position as a sole-source
provider of aftermarket filtration products, pumps, engine
management components and driveline components for many of our
customers.
Expand our Products and Markets Served. We have begun
expansion in several fast-growing product lines that we believe
offer substantial growth opportunities, such as filtration
products for the heavy-duty
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channel and fuel pump assemblies for the aftermarket. We are
also pursuing the growth of our business in the Mexican
aftermarket. According to the 2004/2005 AAIA Aftermarket
Factbook, Mexico has an increasingly large number of vehicles
that are older on average than those in the United States, which
we believe will result in an increased demand for replacement
products. We currently have three manufacturing facilities in
Mexico, and we intend to use the Mexican market as an entry
point into Central and South America, where countries including
Brazil, Chile, and Venezuela may become targets for selective
expansion.
Capitalize on Integration Opportunities. Prior to the
Acquisition, separate back office functions were maintained for
each of our businesses. During the past year, we have been
integrating some of these functions, and we believe that
successful integration of these back office functions, combined
with continued low-cost sourcing and selective plant and
distribution facility consolidation, could generate meaningful
savings for us. However, while we believe there are significant
savings to be gained through integration, our primary focus will
be to share our best practices and to continue to implement lean
manufacturing techniques.
Our Products
We have an extensive product offering made up of over 60,000
parts, which fall into three primary categories:
filtration products, which primarily includes oil,
air and fuel filters; fuel and cooling systems,
which mainly consists of fuel pumps, fuel pump assemblies and
water pumps; and engine, driveline and lighting
systems, which is comprised of engine management
components, drive shafts and u-joints, lighting systems and
specialty distribution services.
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2004 |
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Percent of |
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Net Sales |
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Total Net |
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(in millions) |
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Sales |
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Description |
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Filtration Products
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$ |
368.7 |
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35.9 |
% |
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Oil, air, fuel, hydraulic, transmission, cabin air and
industrial filters |
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Fuel and Cooling Systems
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339.3 |
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33.1 |
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Mechanical fuel pumps, electric fuel pumps, fuel pump assemblies
and fuel pump strainers, water pumps, water outlets and fan
clutches |
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Engine, Driveline and Lighting Systems
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318.7 |
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31.0 |
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Engine management components, universal joints, driveshafts and
components, CV joints and signal lighting equipment |
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Total Net Sales
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$ |
1,026.7 |
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100.0 |
% |
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6
We are a leading designer and manufacturer of a broad range of
filtration products for the automotive, trucking, construction,
mining, agriculture and marine industries, as well as other
industrial markets. We distribute into both the original
equipment manufacturer and the aftermarket channels. We are one
of the leading global manufacturers of private label filter
products for companies such as AutoZone, GM and Valvoline. Our
filtration product offering consists of approximately 4,000
parts and includes oil filters, air filters, fuel filters,
transmission filters, cabin air filters, PCV valves, hydraulic
filters, fuel dispensing filters and fuel/water separators.
Filtration products comprised approximately 36% of our net sales
in 2004. The table below summarizes our filtration products.
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| Products |
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Description |
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Oil Filters
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Designed to filter engine oil and withstand operating pressures
of 40 to 60 PSI at 250° F to 300° F. |
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Air Filters
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Designed to filter the air that enters the engine combustion
chamber. |
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Fuel Filters
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Designed to filter the fuel immediately prior to its injection
into the engine. |
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Other Filters
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Includes cabin air filters, transmission filters, hydraulic
filters, PCV valves and industrial filters. |
In an effort to improve our cost structure, in 2001 we completed
construction of a new manufacturing facility in Saltillo,
Mexico. Also, in the third quarter of 2003, we completed an
$18.6 million major expansion and efficiency improvement
project at our Albion, Illinois manufacturing site. This effort
was the first phase in a two-phase capital investment plan
designed to improve operating efficiency and lower costs.
In 2003, we initiated the second phase of the capital investment
plan. This $32.0 million project has been in process for
all of 2004 and is expected to be completed in the second
quarter of 2005. Among other things, the project adds two new
high-speed oil assembly lines in Albion and relocates most of
the West Salem, Illinois operations to Albion. We expect this
phase to generate additional manufacturing capacity and lower
our overall manufacturing costs, which we believe will position
us to pursue new business opportunities and market share.
We are also focused on increasing our penetration into the
heavy-duty channel. The heavy-duty channel represents our most
significant opportunity for growth with respect to filtration,
and we believe that our heavy-duty sales could experience
meaningful growth for our Luber-finer branded filters. In 2004,
we achieved a significant sales increase in this channel and
expect continued growth in the future. We have invested capital
to improve capacity utilization, employee productivity and
distribution in this channel, which enabled us to manufacture a
greater proportion of our heavy-duty product line.
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Automotive Filter Aftermarket |
Based on 2004 point-of-sale data gathered from NPD Automotive
and information contained in Frost & Sullivans
2001 North America Automotive Filter Aftermarket Report
No. 7886-18, we estimate the total North American
automotive filter market to be approximately $1.3 billion.
Oil filters represent 39.1% of the filter market with
approximately $525 million in revenue. Air filters
represent 38.9% of the filter market with approximately
$522 million in revenue. Fuel filters represent 15% of the
filter market with $201 million in revenue. Transmission
filters represent 6.6% of the filter market with
$88 million in revenue. Cabin air filters represent 0.4% of
the filter market with $6 million in revenue.
According to the Frost & Sullivan 2001 filter report,
at that time period the North American automotive filter
aftermarket was comprised of several large manufacturers with
UIS, Honeywell Consumer Product Group (FRAM), ArvinMeritor
(Purolator), and The Affinia Group (Wix) controlling
approximately 90% of the market with shares split relatively
evenly among the four companies. Management estimates that this
mix
7
has remained relatively consistent through 2004. In the
heavy-duty channel, we believe our market share ranks behind
Cummins, Donaldson and Clarcor.
We design and manufacture a broad range of fuel and cooling
systems. Our fuel and cooling systems are distributed to both
the OEM and the aftermarket under the Airtex and Master Parts
brand names and some private labels. The table below summarizes
our fuel and cooling system products.
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| Products |
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Description |
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Fuel Pumps
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Serve the essential role of moving fuel from the fuel tank into
the engine, with approximately 850 fuel pumps for carbureted and
fuel-injected applications |
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Fuel Pump Assemblies
|
|
Provide for easier, and therefore faster, installation and allow
the technician to charge a similar fee for a repair that is less
time-intensive than replacing an individual fuel pump, we
manufacture all three types of in-tank assemblies: hangers,
senders and modules, with approximately 400 in-tank fuel pump
assemblies |
|
Water Pumps
|
|
Serve the essential role of dissipating excess heat from the
engine, with approximately 1,300 distinct types of water pumps |
|
Other
|
|
Includes fuel pump strainers, fan clutches and water outlets
with a selection of approximately 850 other part numbers |
We continue to pursue a series of cost-savings initiatives
related to our water pump product line. These initiatives
include the consolidation of water pump production into a single
site. In addition, a global sourcing/production initiative for
key components has been executed. We believe these initiatives
have positioned us to take advantage of lower-cost labor rates
and reduced manufacturing costs to help ensure our ongoing
competitive cost position in water pumps.
We are also in the process of reconfiguring and consolidating
our fuel pump production. This project is scheduled for
completion in the first half of 2005 and is expected to improve
efficiency and cycle time and reduce cost.
To strengthen our OEM market share in fuel systems, we have
recently developed two new programs: demand delivery returnless
fuel systems and a fuel-conditioning module for diesel
applications. Our demand delivery returnless fuel system
utilizes a patented electronic system, engineered to control the
responses of a comprehensive fuel pump process for light
vehicles. To complement the demand delivery program for the
diesel market, we have co-developed a fuel-conditioning module
with Parker Hannifin Corp. This system has expanded our
relationships with Parker Hannifin, Caterpillar and other OEM
customers.
The fuel pump aftermarket and OEM market are comprised of
several large manufacturers. According to the 2003 United States
Automotive Fuel Pump Aftermarket Report No. A542-18
prepared by Frost & Sullivan, in 2003, we and our top
competitor together controlled 59% of the U.S. electric
fuel pump aftermarket. Our primary competitors are ASC
Industries, Inc., Carter/ Federal-Mogul, Bosch, and GMB North
America Inc.
|
|
|
Engine, Driveline and Lighting Systems |
Four of our wholly owned subsidiaries, Wells Manufacturing,
Neapco, Flexible Lamps and Pioneer, produce and provide products
that we describe as our engine, driveline and lighting systems.
These businesses consist of four broad product lines, which
include engine management systems, driveline products, lighting
systems and specialty distribution. U.S. sales account for
approximately 79% of our engine, driveline and lighting systems
revenues, while international sales constitute the remaining
21%. Approximately 86% of the 2004 sales outside of the
U.S. were made in Europe, while the balance of the sales
were predominantly made in Canada and Mexico.
8
We believe that we have one of the industrys most
comprehensive lines of highly engineered engine management
system components, commercial lighting systems and driveline
components for use in a broad range of vehicle platforms.
Additionally, our engine, driveline and lighting systems
offerings allow us to distribute specialty or
hard-to-find products to the aftermarket and OEM
channels. The following table summarizes our engine, driveline
and lighting systems products.
| |
|
|
| Products |
|
Description |
| |
|
|
|
Engine Management Components
|
|
Engine management components include distributor caps and
rotors, ignition coils, electronic controls, sensors, emissions
components, solenoids, switches, voltage regulators and wire
sets. These products are primarily used to regulate the
ignition, emissions and fuel management functions of the engine
and determine vehicle performance. Replacement rates for these
products are higher for vehicles that have been on the road more
than 10 years. Our product offering in this category
consists of approximately 26,000 part numbers. |
|
Driveline Components
|
|
These components include universal joints; automotive,
agricultural and specialty drive shafts and components;
heavy-duty drive shafts and components; CV joints and boot kits
and small vehicle CV half shafts. These products are used in
vehicles to transfer power or to propel equipment. Replacement
rates for these components are more common for vehicles greater
than 10 years old. Our product offering in this category
consists of approximately 6,000 part numbers. |
|
Lighting Systems
|
|
Signal lighting products are used in commercial vehicle
applications such as trucks, trailers, agricultural tractors,
vans, utility and off-road vehicles, construction machinery,
agricultural trailers, horseboxes and buses. Our product
offering in this category consists of approximately 2,000 part
numbers. |
|
Specialty Distribution
|
|
Our specialty distribution business distributes hard-to-find
products in categories such as engine, power train, mounts,
clutch and clutch bearings and bushings, high performance and
shop supplies. Our product offering in this category consists of
approximately 21,000 part numbers. |
The competitors for our engine, driveline and lighting systems
businesses are involved in manufacturing and distributing engine
management systems, driveline components and lighting systems to
the aftermarket, as well as aftermarket specialty distribution.
Within the North American engine management components
aftermarket, Standard Motor Products, AC Delco, Delphi, and
Bosch are our largest competitors. The market for driveline
components is comprised of small private manufacturers and
divisions of large, multi-national manufacturers. The European
signal lighting equipment market competition is concentrated
among a select number of large, multi-product automotive
suppliers and several smaller manufacturers that focus primarily
on lighting products. Our direct competition in the North
American specialty distribution market comes primarily from
small, family-owned operations. Many of these companies are
niche industry participants with narrow product line offerings.
Our Sales Channels and Customers
As of December 31, 2004, we distributed our products to
more than 9,000 customers across several sales channels,
including the retail, traditional, installer, and OES
aftermarket channels and OEMs of automotive, trucking,
agricultural, marine, mining and construction equipment. We have
maintained longstanding relationships with our customers and
have been servicing many for well over a decade. Some of our
most significant customers include AutoZone, GM, CARQUEST, Ford,
Valvoline and Advance Auto Parts. Sales to AutoZone were
approximately 22% and 23% of our total net sales in 2004 and
2003, respectively. Over the last few years, we believe several
customers transitioned to us as a result of their need for
improved product quality and service.
9
The following table provides a description of the various sales
channels to which we supply our products.
| |
|
|
|
|
|
|
| Sales Channel |
|
Description |
|
Examples | |
| |
|
|
|
| |
|
Retail
|
|
Retail stores, including national chains, that sell replacement
parts to consumers that do their own vehicle maintenance,
referred to as do-it-yourselfers or DIY |
|
|
AutoZone, Advance Auto Parts |
|
|
Traditional
|
|
Traditional distribution channel composed of established
warehouses that are the primary source of products for
professional mechanics, referred to as do-it-for-me
or DIFM |
|
|
CARQUEST, NAPA |
|
|
Installer
|
|
Supplies the national and regional service chains through
distributors, many of which sell products under their own
proprietary labels |
|
|
Valvoline, Mighty |
|
|
OES
|
|
Original equipment service market includes service bays at
automotive and heavy-duty dealerships serving the aftermarket.
Usually set up as service organization under the original
equipment manufacturers, for example the GM Service Parts
Organization |
|
|
Ford, GM |
|
|
OEM
|
|
Original equipment manufacturers consist of the companies that
manufacture vehicles |
|
|
Ford, GM, DaimlerChrysler |
|
|
Heavy Duty
|
|
Products supplied either to OEMs or in the aftermarket for use
in class 6, 7 and 8 trucks and other large vehicles |
|
|
Freightliner, Caterpillar |
|
Our sales are diversified between the retail, traditional,
installer, OES, heavy-duty and OEM channels, which enables us to
capture demand throughout the life cycle of the vehicle. In the
early part of a vehicles life, the OES channel services a
significant percentage of aftermarket vehicle maintenance and
repair volume. However, as vehicles age and their warranties
expire, consumers increasingly rely on the retail or traditional
channels for vehicle maintenance.
We estimate that about 77% of our net sales in 2004 were to the
aftermarket, which is subdivided into five primary channels:
retail, traditional, installer, heavy duty and OES.
The retail channel represented approximately 29% of our net
sales in 2004, and includes national retailers such as AutoZone
and Advance Auto Parts. The retail channel is our largest
channel and has historically provided us with a steadily
increasing revenue stream. As retailers become increasingly
focused on consolidating their supplier base, we believe that
our broad product offering, product quality and customer service
make us increasingly valuable to these customers. One of our
longest standing customers is AutoZone, which we have been
supplying since the opening of their first store in 1979. We
believe that we are one of the few suppliers in the industry
that can provide AutoZone with the levels of quality, customer
service and product breadth that AutoZone requires, which is
substantiated by our receipt of multiple awards from AutoZone
since 1994. Awards from other customers include Automotive Parts
Associates Preferred Vendor of the Year 2003, Advance Auto Parts
Vendor of the Year 2002, and National Pronto Supplier of the
Year 1998.
The traditional distribution channel is composed of established
warehouses and represented approximately 20% of our net sales in
2004. The traditional channel is important to us because it is
the primary source of products for professional mechanics, or
the DIFM market. We have many longstanding relationships with
leading customers in the traditional channel, such as CARQUEST
and NAPA, for whom we have manufactured products for over
20 years. We believe that our strong position in this
channel allows us to capitalize on the growth of the traditional
channel within the aftermarket. We believe that professional
mechanics place a premium on the quality of a product, and
unlike the retailer and installer channels, end users in this
channel require manufacturers to provide a high level of
individual customer service, including field support and product
breadth and depth.
10
The installer channel represented approximately 8% of our net
sales in 2004 and includes quick lubes, tire dealers and full
service gas stations. Almost all of our sales into this channel
consist of filtration products, which are supplied to the
national and regional service chains through distributors such
as Valvoline and Mighty. We believe the installer channel is a
growth area for our filtration products, because consumers
increasingly prefer to have professionals maintain their
vehicles as vehicles become increasingly complex. This channel
requires just-in-time availability, ability to meet competitive
price points, and product breadth and depth.
We believe the large and highly fragmented heavy-duty channel,
which accounted for approximately 10% of our net sales in 2004,
provides us with one of our best opportunities for growth. We
believe heavy-duty truck owners tend to be less price-sensitive
and more diligent about maintenance of their vehicles than
vehicle owners in other markets, as idle vehicles typically
represent lost revenue potential for heavy-duty truck owners. As
a result, we believe that heavy-duty trucks are more likely to
have consistent routine maintenance performed with high quality
parts. We believe we have developed a well-recognized brand
presence in this channel through our Luber-finer brand of
filtration products.
The OES channel is comprised of a diverse mix of dealership
service bays in the automotive, truck, motorcycle and watercraft
vehicle markets, and represented approximately 10% of our net
sales in 2004. In 2004, we estimate that a substantial majority
of our OES net sales were derived from sales of filtration
products. Our position in this channel allows us to capitalize
on vehicle maintenance in the early years of a vehicles
life, when the vehicle is under warranty and the consumer
typically returns to the dealer for routine maintenance. Our
most significant OES channel customers include automotive
dealerships associated with companies such as GM, Ford and
DaimlerChrysler.
|
|
|
Original Equipment Manufacturers |
Although the OEM channel comprised less than 20% of our net
sales in 2004, it is an important sales channel to us because
OEM affiliations have a direct impact on our aftermarket
credibility. We believe aftermarket customers show a preference
for products that were utilized in original equipment. We sell
products to a diverse mix of OEMs, enabling us to capitalize on
a number of different opportunities and market shifts. Our OEM
products are sold to end users within each of the following
categories:
|
|
|
| |
|
Automotive GM, Ford, DaimlerChrysler, Volkswagen and
Mazda |
| |
| |
|
Recreational Equipment Polaris and Onan |
| |
| |
|
Heavy-duty Truck Freightliner, Caterpillar and GM |
| |
| |
|
Agriculture John Deere and Kubota |
| |
| |
|
Marine OMC, Mercury Marine, and Sierra Supply |
| |
| |
|
Lawn and Garden Briggs and Stratton, Kohler and John
Deere |
| |
| |
|
Motorcycle Harley-Davidson and Kawasaki |
We have earned a number of awards and certifications for
customer service and product quality, including General
Motors Supplier of the Year award in 1995 and 1996,
Fords Preferred Quality Award from 1984 through 2003,
Caterpillars Certified Supplier Award from 1996 to 2002
and John Deeres Quality Certification Award from 1996
through 2003.
Sales Organization
We market our products predominantly throughout North America
and Europe. To effectively address the requirements of our
customers and end users, our sales people are primarily
organized by product category and secondarily by sales channel.
We use both direct sales representatives and independent
manufacturers representatives to market and sell our
products. The number of sales personnel varies within each sales
group, ranging from under 10 people in our French sales team for
lighting systems to over 100 in our aftermarket sales group for
fuel and cooling system products. Each sales group is uniquely
qualified to sell their particular products and to focus on the
11
requirements of their particular market. We believe that the
market positions we hold with respect to certain of our products
are, in part, related to the specialization of our sales groups.
Operations
Our operational strategy is to pursue operational excellence at
all of our locations. This initiative encompasses a lean
enterprise strategy, the goals of which include improvement in
inventory management, customer delivery, plant utilization and
cost structure. The foundation for this is lean manufacturing,
which targets the elimination of waste from every business
process. This involves transforming our manufacturing processes
from typical batch systems to single piece flow systems, which
will enable us to better match production to customer demand.
A growing number of our plants continue to make progress in the
implementation of lean manufacturing and have received related
benefits. We plan to continue to expand and accelerate the use
of lean manufacturing across all of our operations. This
expansion is being accomplished by applying additional
resources, outside consultant support, the sharing of best
practices, and the establishment of appropriate metrics and
incentives.
In addition, we will continue to examine each of our logistics
and distribution systems with an objective of developing an
integrated system that fully meets customer requirements,
eliminates redundancies, lowers costs and minimizes inventories
and cycle times.
Suppliers and Raw Materials
We purchase various components and raw materials for use in our
manufacturing processes. We also purchase finished parts for
resale. In 2004, we sourced such purchases from approximately
1,400 suppliers. One of our primary raw materials is steel, for
which global demand has been high since early in 2004, resulting
in price increases and/or surcharges. While we have been, and
expect to continue to be, able to obtain sufficient quantities
to satisfy our needs, we have been required to pay significantly
higher prices for steel. The other primary raw materials that we
use include brass, iron, rubber, resins, plastic, paper and
packaging material, each of which is available in sufficient
quantities from numerous sources. We have not historically
experienced any shortages of these items.
Historically, each of our product groups has had its own
purchasing staff, which makes its purchasing decisions. We have
formed a centralized purchasing group, which has begun to
facilitate the spread of best practices and will enable us to
leverage the buying power of all of UCI. That central group will
continue to be supported by a smaller number of product group
level purchasing personnel making many of the day-to-day
purchasing decisions. We believe that centralized procurement
and increased global sourcing represent attractive opportunities
to lower the cost of our purchased materials.
Trademarks and Patents
We rely on a combination of patents, trademarks, copyright and
trade secret protection, employee and third-party non-disclosure
agreements, license arrangements and domain name registrations
to protect our intellectual property. We sell many of our
products under a number of registered trademarks, which we
believe are widely recognized in the sales channels we serve. No
single patent, trademark or trade name is material to our
business as a whole.
Any issued patents that cover our proprietary technology and any
of our other intellectual property rights may not provide us
with adequate protection or be commercially beneficial to us.
The issuance of a patent is not conclusive as to its validity or
its enforceability. Our competitors may also be able to design
around our patents. If we are unable to protect our patented
technologies, our competitors could potentially commercialize
our technologies.
With respect to proprietary knowledge and methodologies, we rely
on trade secret protection and confidentiality agreements.
Monitoring the unauthorized use of our technology is difficult,
and the steps we have taken may not prevent unauthorized use of
our technology. The disclosure or misappropriation of our
intellectual property could harm our ability to protect our
rights and our competitive position.
12
Employees
As of December 31, 2004, we had approximately 6,900
employees and several different union affiliations and
collective bargaining agreements across our businesses, mostly
concentrated in Mexico, representing approximately 19% of our
workforce. Management considers our labor relations to be good
and our labor rates competitive. Since 1984, we have had two
minor work stoppages, one a short-term stoppage in April 1997 at
one of our smaller plants in Pottstown, Pennsylvania and the
other, a three-day work stoppage at a Fairfield, Illinois plant
in August 2004. The 2004 work stoppage did not result in any
material change in capacity or operations at the plant or the
business as a whole.
Environmental and Health and Safety Matters
We are subject to a variety of Federal, state, local and foreign
environmental laws and regulations, including those governing
the discharge of pollutants into the air or water, the
management and disposal of hazardous substances or wastes and
the cleanup of contaminated sites. Some of our operations
require environmental permits and controls to prevent and reduce
air and water pollution, and these permits are subject to
modification, renewal and revocation by issuing authorities. We
are also subject to the U.S. Occupational Health and Safety
Act and similar state and foreign laws. We believe that we are
in substantial compliance with all applicable material laws and
regulations in the United States. Historically, our costs of
achieving and maintaining compliance with environmental and
health and safety requirements have not been material to our
operations.
We have been identified as a potentially responsible party for
contamination at two sites. One of these sites is a former
facility in Edison, New Jersey, where a state agency has ordered
the Company to continue with the monitoring and investigation of
chlorinated solvent contamination. The Company has informed the
agency that this contamination was caused by another party at a
neighboring facility and has initiated a lawsuit against that
party for damages and to compel it to take responsibility for
any further investigation or remediation. The second site is a
previously owned site in Solano County, California, where the
Company, at the request of the regional water board, is
investigating and analyzing the nature and extent of the
contamination and is conducting some remediation. Based on
currently available information, management believes that the
cost of the ultimate outcome of these environmental matters will
not exceed the amounts accrued at December 31, 2004 by a
material amount, if at all.
13
We currently maintain 24 manufacturing facilities, 18 of which
are located in North America and six in Europe. In addition, we
maintain 12 distribution and warehouse facilities. Listed below
are the locations of our principal manufacturing facilities:
| |
|
|
|
|
|
|
|
|
| Product |
|
|
|
Owned/ |
|
Square |
|
|
| Category |
|
Location |
|
Leased |
|
Footage |
|
Products Manufactured |
| |
|
|
|
|
|
|
|
|
|
Filtration Products
|
|
Albion, Illinois I |
|
Owned |
|
334,241 |
|
Spin-on Oil Filters; Heavy-duty Lube Filters; Micro Glass
Elements |
| |
|
Albion, Illinois II |
|
Owned |
|
50,879 |
|
Spin-on Oil Filters |
| |
|
Albion, Illinois III |
|
Owned |
|
49,672 |
|
Heavy-duty Lube Units |
| |
|
Albion, Illinois IV |
|
Owned |
|
101,788 |
|
Heavy-duty Air Filters; Radial Air Filters; Automotive Conical
and Radial Air Filters; Plastisol Panel Air Filters |
| |
|
Shelby Township, Michigan |
|
Leased |
|
31,694 |
|
Auto Fuel Filters |
| |
|
West Salem, Illinois |
|
Owned |
|
195,793 |
|
Heavy-duty Lube Filters; Spin-on Oil Filters |
| |
|
York, South Carolina |
|
Owned |
|
187,570 |
|
Auto Spin-on Oil Filters |
| |
|
Saltillo, Mexico |
|
Owned |
|
205,070 |
|
Auto Spin-on Oil Filters; Panel Air Filters; Fuel Filters;
Elements Lube/Fuel; Round Air Filters |
| |
|
Mansfield Park, United Kingdom |
|
Leased |
|
107,116 |
|
Radial Seal Air Filters; Poly Panel Air Filters; Heavy-duty Air
Filters; Dust Collection Filters |
|
Fuel and Cooling Systems
|
|
Fairfield, Illinois I |
|
Owned |
|
148,067 |
|
Plating, Heat Treat and Welding Fuel Pump Components |
| |
|
Fairfield, Illinois II |
|
Owned |
|
418,811 |
|
Electric Fuel Pump Assemblies and Components; Mechanical Fuel
Pumps and Components; Water Pump Assemblies Components |
| |
|
Marked Tree, Arkansas |
|
Owned |
|
287,000 |
|
Water Pump Components; Electric and Mechanical Fuel Pump
Components; Plastic Moldings; Water Pump Assemblies |
| |
|
Feltham, United Kingdom |
|
Leased |
|
34,212 |
|
Water Pump, Oil Pump, and Variable Valve Control Unit (VVC)
Components; Electric Water Pump Assemblies; Water Pump and Oil
Pump Assemblies; VVC Assemblies |
| |
|
Zaragoza, Spain |
|
Owned |
|
34,408 |
|
Water Pump Components; Water Pump Assemblies |
| |
|
Winnipeg, Canada |
|
Owned |
|
29,838 |
|
Electric and Mechanical Fuel Pumps; Electric and Mechanical Fuel
Pump Assemblies |
| |
|
Puebla, Mexico |
|
Owned |
|
118,299 |
|
Gray Iron Foundry Castings; Water Pump Seal Assemblies; Water
Outlets; Water Pump Assemblies and Components |
14
| |
|
|
|
|
|
|
|
|
| Product |
|
|
|
Owned/ |
|
Square |
|
|
| Category |
|
Location |
|
Leased |
|
Footage |
|
Products Manufactured |
| |
|
|
|
|
|
|
|
|
|
Engine, Driveline and Lighting Systems
|
|
Reynosa, Mexico |
|
Owned |
|
107,500 |
|
Coils; Distributor Caps and Rotors; Sensors; Solenoids; Switches
and Wire Sets; 5,000 square feet utilized for Fuel and Cooling
Systems |
| |
|
Pottstown, Pennsylvania |
|
Owned |
|
215,000 |
|
Automotive; Agricultural and Specialty Driveshafts; Heavy-duty
Driveshafts and Components; Heavy-duty Universal Joints |
| |
|
Beatrice, Nebraska |
|
Owned |
|
170,000 |
|
CV Joints and Boot Kits; CV Halfshafts; Automotive Universal
Joints |
| |
|
Fond du Lac, Wisconsin I |
|
Owned |
|
187,750 |
|
Distributor Caps and Rotors; Components |
| |
|
Fond du Lac, Wisconsin II |
|
Owned |
|
36,000 |
|
Electronic Controls; Sensors; Voltage Regulators |
| |
|
Essex, United Kingdom I |
|
Owned |
|
75,100 |
|
Rubber and Plastic Moldings; Plasma Coated Components; Finished
Lamps; Reflectors |
| |
|
Essex, United Kingdom II |
|
Owned |
|
68,000 |
|
Phasa Machinery |
| |
|
Suffolk, United Kingdom |
|
Owned |
|
40,000 |
|
Plastic Moldings; Wiring Harness; Finished Lamps; Junction
Boxes; Trailer Connections |
|
|
| ITEM 3. |
LEGAL PROCEEDINGS |
We are, from time to time, party to various routine legal
proceedings arising out of our business. These proceedings
primarily involve commercial claims, product liability claims,
personal injury claims and workers compensation claims. We
cannot predict the outcome of these lawsuits, legal proceedings
and claims with certainty. Nevertheless, we believe that the
outcome of any currently existing proceedings, even if
determined adversely, would not have a material adverse effect
on our business, financial condition and results of operations.
|
|
| 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 ended December 31, 2004.
PART II
|
|
| ITEM 5. |
MARKET FOR REGISTRANTS COMMON EQUITY AND RELATED
STOCKHOLDER MATTERS |
(a) Market Information
No trading market for our common stock currently exists.
(b) Holders
As of December 31, 2004, our parent, UCI Acquisition
Holdings, Inc. was the sole holder of our common stock.
(c) Dividends
We did not pay dividends in the period from the date of our
incorporation on April 16, 2003 through December 31,
2004 on our common stock. It is our current policy to retain
earnings to repay debt and finance our operations. In addition,
our credit facility and indenture significantly restrict the
payment of dividends on common stock.
15
(d) Securities Authorized for Issuance under Equity
Compensation Plans
None of our securities are offered under any compensation plans.
For a description of the stock option plan granting options for
the purchase of securities of our parent, see Item 11.
Executive Compensation.
|
|
| ITEM 6. |
SELECTED FINANCIAL DATA |
United Components, Inc. was formed in connection with the
Acquisition. The financial statements included in this Annual
Report on Form 10-K (Form 10-K) are the
combined financial statements of the vehicle parts businesses of
UIS before the Acquisition and the consolidated financial
statements of United Components, Inc. after the Acquisition. The
financial data presented below for periods prior to the
Acquisition are referred to as Predecessor Company
Combined, and the financial data for periods after the
Acquisition are referred to as UCI Consolidated. The
selected financial data have been derived from the
companys financial statements. The financial data as of
December 31, 2004 and 2003 and for each of the years in the
three-year period ended December 31, 2004 have been derived
from the audited financial statements contained elsewhere in
this Form 10-K. We derived the combined balance sheet data
as of December 31, 2002, 2001, and 2000 and the combined
statement of income data for the 2001 and 2000 years from
audited combined financial statements that are not included
herein. The data for the periods from June 21, 2003 to
March 31, 2004 are based on a preliminary allocation of the
Acquisition purchase price. Data for periods after
March