SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
FORM 10-K
Annual Report Pursuant to Section 13 or 15(d) of the Securities Exchange Act of 1934
For the Fiscal Year Ended December 31, 2003
Commission File No. 1-12983
GENERAL CABLE CORPORATION
| Delaware | 06-1398235 | |
| (State or other jurisdiction of | (I.R.S. Employer Identification No.) | |
| incorporation or organization) |
4 Tesseneer Drive
Highland Heights, KY 41076-9753
(Address of principal executive offices)
(859) 572-8000
(Registrants telephone number, including area code)
Securities Registered Pursuant to Section 12(b) of the Act:
| Title of Each Class | Name of Each Exchange on which registered | |
| Common Stock, $.01 Par Value | 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, and (2) has been subject to such filing
requirements for the past 90 days.
Yes [X] No [ ]
Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of the Regulation S-K is not contained herein, and need 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 the Form 10-K. [X]
Indicate by check mark whether the registrant is an accelerated filer (as
defined in Exchange Act Rule 12b-2).
Yes [X] No [ ]
As of June 30, 2003, there were 33,104,800 shares of the Registrants Common Stock outstanding. The aggregate market value of Common Stock held by non-affiliates was $176 million (based upon non-affiliate holdings of 32,534,900 shares and a market price of $5.40 per share).
Documents Incorporated by Reference:
Proxy Statement for the 2004 Annual Meeting of Shareholders (portions of which are incorporated by reference in Part III hereof).
GENERAL CABLE CORPORATION
INDEX TO ANNUAL REPORT
ON FORM 10-K
| PAGE |
||||
PART I |
||||
Item 1. |
Business | 3 | ||
Item 2. |
Properties | 11 | ||
Item 3. |
Legal Proceedings | 12 | ||
Item 4. |
Submission of Matters to a Vote of Security Holders | 14 | ||
PART II |
||||
Item 5. |
Market for Registrant's Common Stock and Related Stockholder Matters | 14 | ||
Item 6. |
Selected Financial Data | 15 | ||
Item 7. |
Management's Discussion and Analysis of Financial Condition and Results of Operations | 17 | ||
Item 7A. |
Quantitative and Qualitative Disclosures About Market Risk | 30 | ||
Item 8. |
Financial Statements and Supplementary Data | 32 | ||
Item 9. |
Changes in and Disagreements with Accountants on Accounting and Financial Disclosure | 32 | ||
Item 9A. |
Controls and Procedures | 32 | ||
PART III |
||||
Item 10. |
Directors and Executive Officers of the Registrant | 33 | ||
Item 11. |
Executive Compensation | 34 | ||
Item 12. |
Security Ownership of Certain Beneficial Owners and Management | 34 | ||
Item 13. |
Certain Relationships and Related Transactions | 34 | ||
Item 14. |
Principal Accounting Fees and Services | 34 | ||
PART IV |
||||
Item 15. |
Exhibits, Financial Statement Schedules, and Reports on Form 8-K | 34 | ||
Signatures |
39 |
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PART I.
Item 1. Business
General Cable Corporation (the Company) is a leading global developer and manufacturer in the wire and cable industry. The Companys operations are divided into three main segments: energy, industrial & specialty and communications. Energy cable products include low-, medium- and high-voltage power distribution and power transmission products for overhead and buried applications. Industrial & specialty wire and cable products conduct electrical current for industrial, OEM, commercial and residential power and control applications. Communications wire and cable products transmit low-voltage signals for voice, data, video and control applications. The Company has a leading market position in each of the segments in which it competes due to product, geographic and customer diversity and the Companys ability to operate as a low cost provider. The Company sells a wide variety of copper, aluminum and fiber optic wire and cable products, which it believes represents the most diversified product line of any U.S. manufacturer. As a result, the Company is able to offer its customers a single source for most of their wire and cable requirements. The Company manufactures its product lines in 27 facilities and sells its products worldwide through its operations in North America, Europe and Oceania. Technical expertise and implementation of Lean Six Sigma strategies have allowed the Company to maintain its position as a low cost provider.
The Company is a Delaware corporation and was incorporated in April 1994. Its principal executive offices are located at 4 Tesseneer Drive, Highland Heights, Kentucky 41076-9753 and its telephone number is (859) 572-8000. The Companys internet address is www.generalcable.com. General Cables annual report on Form 10-K, quarterly reports on Form 10-Q and current reports on Form 8-K, and amendments to those reports filed or furnished pursuant to Section 13(a) or 15(d) of the Exchange Act, are made available free of charge at www.generalcable.com as soon as reasonably practicable after we electronically file such material with, or furnish it to, the Securities and Exchange Commission (SEC). In addition, the Company will provide, at no cost, paper or electronic copies of our reports and other filings made with the SEC. Requests should be directed to: Investor Relations, General Cable Corporation, 4 Tesseneer Drive, Highland Heights, KY 41076.
The information on the website listed above is not and should not be considered part of this annual report on Form 10-K and is not incorporated by reference in this document. This website is and is only intended to be an inactive textual reference.
The Company and its predecessors have served various wire and cable markets for over 150 years. The Companys immediate predecessor (Predecessor) was a unit of American Premier Underwriters, Inc. (American Premier), previously known as The Penn Central Corporation. American Premier acquired the Companys existing wire and cable business in 1981 and significantly expanded the business between 1988 and 1991 by acquiring Carol Cable Company, Inc. and other wire and cable businesses and facilities. In June 1994, a subsidiary of Wassall PLC (Wassall) acquired the Predecessor by purchase of General Cables outstanding subordinated promissory note, the General Cable common stock held by American Premier and a tender offer for the publicly-held General Cable common stock. Between May and August 1997, Wassall consummated public offerings for the sale of all of its interest in General Cables common stock. The Company has operated as an independent public company since completion of the offerings.
During 1999, the Company acquired the worldwide energy cable and cable systems businesses of Balfour Beatty plc, previously known as BICC plc, with operations in the United States, Canada, Europe, Africa, the Middle East and Asia Pacific for a total purchase price of $385.8 million. This acquisition was accounted for as a purchase, and accordingly, the results of operations of the acquired businesses are included in the consolidated financial statements for periods after the respective closing dates.
In December 1999, the Company decided to sell certain business units due to their deteriorating operating performance. On February 9, 2000, the Company signed a definitive agreement with Pirelli Cavi e Sistemi S.p.A., of Milan, Italy, for the sale of the stock of these businesses for proceeds of $216 million, subject to closing adjustments. The closing adjustments included changes in net assets of the businesses sold since November 30, 1999, resulting from operating losses and other adjustments as defined in the sale agreement. The businesses sold were acquired from BICC plc during 1999 and consisted primarily of the operations in the United Kingdom, Italy and Africa and a joint venture interest in Malaysia. Gross proceeds of $180 million were received during the third quarter of 2000 as a down payment against the final post-closing adjusted purchase price. During the third quarter of 2001, the final post-closing adjusted purchase price was agreed as $164 million resulting in the payment of $16 million to Pirelli. The Company provided for a larger settlement amount in the third quarter of 2000, and therefore, $7 million of income was recognized in the third quarter of 2001.
In September 2000, the Company acquired Telmag S.A. de C.V., a Mexico-based manufacturer of telecommunications cables for $23 million. The acquisition brought additional outside plant telecommunications cable capacity as well as provided available capacity for a broad range of telecommunications cables.
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In March 2001, the Company sold the shares of its Pyrotenax business unit to Raychem HTS Canada, Inc., a business unit of Tyco International, Ltd., for $60 million, subject to closing adjustments. The business unit, with operations in Canada and the United Kingdom, principally produced mineral insulated high-temperature cables. During the second quarter of 2002, the final post-closing adjusted purchase price was agreed and resulted in a payment to Tyco International, Ltd. of approximately $2 million during the third quarter of 2002.
In September 2001, the Company announced its decision to exit the consumer cordsets business. As a result of this decision, the Company closed its Montoursville, Pennsylvania plant. This facility manufactured cordset products including indoor and outdoor extension cords, temporary lighting and extension cord accessories.
In October 2001, the Company sold substantially all of the manufacturing assets and inventory of its building wire business to Southwire Company for $82 million of cash proceeds and the transfer to the Company of certain data communication cable manufacturing equipment. Under the building wire sale agreement, Southwire purchased the inventory and substantially all of the property, plant and equipment located at the Companys Watkinsville, Georgia and Kingman, Arizona facilities and the wire and cable manufacturing equipment at the Companys Plano, Texas facility. The Company retained and continues to operate the copper rod mill in Plano, however it has closed the Plano wire mill. The assets sold were used in manufacturing building wire products principally for the retail and electrical distribution markets.
Beginning in the third quarter of 2001, the Company reported the building wire and cordsets segment as discontinued operations for financial reporting purposes. Administrative expenses formerly allocated to this segment are now reported in the continuing operations segments. Prior periods presented reflect this change.
During the second quarter of 2002, General Cable formed a joint venture company to manufacture and market fiber optic cables. General Cable contributed assets, primarily inventory and machinery and equipment, to a subsidiary company which was then contributed to the joint venture in exchange for a $10.2 million note receivable which resulted in a $5.6 million deferred gain on the transaction.
Products and Markets
Financial information for each of the Companys three main operating segments is summarized below, in millions of dollars:
| Year Ended December 31, |
||||||||||||||||||||||||
| 2003 |
2002 |
2001 |
||||||||||||||||||||||
| Amount |
% |
Amount |
% |
Amount |
% |
|||||||||||||||||||
Net sales: |
||||||||||||||||||||||||
Energy |
$ | 560.2 | 37 | % | $ | 516.0 | 36 | % | $ | 521.8 | 32 | % | ||||||||||||
Industrial & specialty |
542.4 | 35 | % | 499.4 | 34 | % | 537.6 | 32 | % | |||||||||||||||
Communications |
435.8 | 28 | % | 438.5 | 30 | % | 592.0 | 36 | % | |||||||||||||||
Total net sales |
$ | 1,538.4 | 100 | % | $ | 1,453.9 | 100 | % | $ | 1,651.4 | 100 | % | ||||||||||||
Operating income: |
||||||||||||||||||||||||
Energy |
$ | 38.0 | 71 | % | $ | 36.9 | 75 | % | $ | 35.3 | 33 | % | ||||||||||||
Industrial & specialty |
9.9 | 18 | % | 9.7 | 20 | % | 24.3 | 22 | % | |||||||||||||||
Communications |
6.0 | 11 | % | 2.5 | 5 | % | 48.5 | 45 | % | |||||||||||||||
Subtotal |
53.9 | 100 | % | 49.1 | 100 | % | 108.1 | 100 | % | |||||||||||||||
Corporate and other operating
items |
(8.2 | ) | (33.4 | ) | (3.8 | ) | ||||||||||||||||||
Total operating income |
$ | 45.7 | $ | 15.7 | $ | 104.3 | ||||||||||||||||||
| December 31, |
||||||||
| 2003 |
2002 |
|||||||
Total assets: |
||||||||
Energy |
$ | 269.5 | $ | 229.1 | ||||
Industrial & specialty |
325.1 | 289.9 | ||||||
Communications |
302.9 | 318.3 | ||||||
Corporate |
152.0 | 136.0 | ||||||
Total assets |
$ | 1,049.5 | $ | 973.3 | ||||
4
The principal products, markets, distribution channels and end-users of each of the Companys product categories are summarized below:
| Product Category |
Principal Products |
Principal Markets |
Principal End-Users |
|||
Energy |
||||||
Utility
|
Low-Voltage, Medium-Voltage Distribution; Bare Overhead Conductor; High-Voltage Transmission Cable |
Power Utility | Investor-Owned Utility Companies; State and Local Public Power Companies; Rural Electric Associa- tions; Contractors |
|||
Industrial & Specialty |
||||||
Instrumentation, Power, Control and Specialty |
Rubber and Plastic- Jacketed Wire and Cable; Power and Industrial Cable; Instrumentation and Control Cable |
Industrial Power and Control; Utility/Marine/ Transit; Military; Mining; Oil and Gas; Industrial; Power Generation; Infrastructure; Residential Construction |
Industrial Con- sumers; Contractors; OEMs; Military Customers; Telecom- munication System Operators |
|||
Automotive
|
Ignition Wire Sets; Booster Cables | Automotive Aftermarket |
Consumers; OEMs | |||
Communications |
||||||
Outside Voice and Data (Telecommunications) |
Outside Plant Telecommunications Exchange Cable; Outside Service Wire |
Telecom Local Loop | Telecommunications System Operators |
|||
Data Communications
|
Multi-Conductor/Multi-Pair; Fiber
Optic; Shipboard; Military Fiber Cable |
Computer Networking and Multimedia Applications |
Contractors; OEMs; Systems Integrators; Systems Operators; Military Customers |
|||
Electronics
|
Multi-Conductor; Coaxial; Sound, Security/Fire Alarm Cable |
Building Management; Entertainment; Equipment Control |
Contractors; Consumers; Industrial |
|||
Assemblies
|
Cable Harnesses; Connector Cable |
Telecommunications; Industrial Equipment; Medical Equipment |
Communications and Industrial Equipment Manufacturers |
The Company operates its businesses globally, with 69% of net sales in 2003 generated from North America, 25% from Europe and 6% from Oceania.
Industry and Market Overview
The wire and cable industry is competitive, mature and cost driven. The wire and cable market has declined in recent years, which is directly related to the global economic slowdown experienced in 2001 and 2002 and has resulted in reduced spending by customers in all wire and cable markets as well as price erosion caused in part by excess manufacturing capacity. Wire and cable products are relatively low value added, higher weight (and therefore relatively expensive to transport) and often subject to regional or country specifications. In many business segments there is little differentiation among participants from a manufacturing standpoint. The industry is highly fragmented with many participants in both the United States and worldwide. Since the 1990s, the industry has been undergoing consolidation. Additionally, over the past few years, some large market participants have been willing to divest businesses that are underperforming or not perceived as good growth opportunities. The wire and cable industry is raw materials intensive with copper and aluminum comprising the major cost component for cable products. Changes in the cost of copper and aluminum are generally passed through to the customer, although there can be timing delays of varying lengths depending on the volatility in metal prices, the type of product, competitive conditions and particular customer arrangements.
5
Energy
The energy market consists of low-, medium- and high-voltage power distribution and power transmission products for overhead and buried applications. Growth in this market will be largely dependent on investment policy of electric utilities and infrastructure improvement. The Company believes that the increase in electricity consumption in North America has outpaced the rate of utility investment in power cables. As a result, the Company believes the average age of power transmission cables has increased, the current electric transmission infrastructure needs to be upgraded and the transmission grid is near capacity. In addition, the 2003 power outages in the U.S., Canada and Europe emphasize the need for upgrading the power transmission infrastructure used by electric utilities which may, over time, cause an increase in demand for the Companys products.
The Company is a leader in the supply of energy cables to the North America electric utility industry. The business manufactures low- and medium-voltage aluminum and copper distribution cable, bare overhead aluminum conductor and high-voltage transmission cable. Bare transmission cables are utilized by utilities in the transmission grid to provide electric power from the power generating stations to the distribution sub-stations. Medium-voltage energy cables are utilized in the primary distribution infrastructure to bring the power from the distribution sub-stations to the transformers. Low-voltage energy cables are utilized in the secondary distribution infrastructure to take the power from the transformers to the end-users meter.
The Companys North American energy cables business has strategic alliances in the United States and Canada with a number of major customers and is strengthening its position through these agreements. This business utilizes a network of direct sales and authorized distributors to supply low- and medium-voltage and bare overhead cable products. This market is represented by approximately 3,500 utility companies.
The Company anticipates that sales volume for North American customers should improve over time as utility customers address capital projects that were previously deferred, including enhancements to the power transmission and distribution grid. In 2003, projects were not released as quickly as expected which management believes is partially due to proposed energy legislation in the United States which would provide future regulatory relief and allow North American utility companies to earn an adequate rate of return on their investment in upgrading the transmission grid infrastructure. In addition, certain other proposed legislation in the United States, if passed, will permit accelerated depreciation on transmission grids, certain tax credits and bonus depreciation on new equipment which could create an increased demand for the Companys products.
A majority of the Companys North America energy market customers have entered into written agreements with it for the purchase of wire and cable products. These agreements typically have 2-4 year terms, do not guarantee a minimum level of sales and provide metal adjustments to selling prices to reflect fluctuations in the price of copper and aluminum. Historically, approximately 70% of our North America energy business is contracted for prior to the start of each year.
The Companys European energy cables business is headquartered in Barcelona, Spain and is a strong regional wire and cable manufacturer in Europe. The business utilizes its broad product offering and its low cost manufacturing platform to gain market share as evidenced by its award in 2003 of business with utilities in France, Italy and the United Kingdom. The business has also benefited from its competitors ongoing withdrawal of medium-voltage cable manufacturing capacity from the European market and from the trend in Europe to install power cables underground, which requires more highly engineered cables.
Industrial & Specialty
The industrial & specialty market consists of wire and cable products for use in a wide variety of capital goods and consumer uses. The principal product categories in this market are portable cord, industrial cables and automotive products.
The global market for industrial & specialty cable products has many niche markets. Sales in North America have declined in recent years as the result of a substantial decline in industrial construction spending from mid-1990 peak levels. Growth in the industrial & specialty markets will be largely dependent upon new industrial construction, investment in capital equipment and vehicle after-market maintenance spending.
Many industrial and commercial wire and cable applications require cables with exterior armor and/or jacketing materials that can endure exposure to chemicals, extreme temperatures and outside elements. The Company offers products that are specifically designed for these applications.
Portable Cord and Specialty Cables. The Company manufactures and sells a wide variety of rubber and plastic insulated portable cord products for power and control applications serving industrial, mining, entertainment, OEM, farming and other markets. Portable cord products are used for the distribution of electrical power, but are designed and constructed to be used in dynamic and severe environmental conditions
6
where a flexible but durable power supply is required. Portable cord products include both standard commercial cord and cord products designed to meet customer specifications. Portable rubber-jacketed power cord, the Companys largest selling cord product line, is typically manufactured without a connection device at either end and is sold in standard and customer-specified lengths. Portable cord is also sold to OEMs for use as power cords on their products and in other applications, in which case the cord is made to the OEMs specifications. The Company also manufactures portable cord for use with moveable heavy equipment and machinery. The Companys portable cord products are sold primarily through electrical distributors and electrical retailers to industrial customers, OEMs, contractors and consumers.
The Companys portable cords are used in the installation of new industrial equipment and the maintenance of existing equipment, and to supply electrical power at temporary venues such as festivals, sporting events, concerts and construction sites. The Company expects demand for portable cord to be influenced by general economic activity.
The Companys industrial & specialty products sold under the Brand Rex name include low-voltage and data transmission cables, rail and mass transit cables, shipboard cables, off-shore cables, other industrial cables and cables that meet low-smoke, zero-halogen requirements in Europe. Primary uses for these products include various applications within power generating stations, marine, oil and gas, transit/locomotive, OEMs, machine builders, medical imaging, shipboard, aerospace industries, space flight and aircraft markets. Shipboard cables sold by the Company hold a leading position with the U.S. Navy. The Companys Polyrad XT marine wire and cable products also provide superior properties and performance levels that are necessary for heavy-duty industrial applications to both onshore and offshore platforms, ships and oil rigs.
Industrial cable products include medium and low voltage power, control and instrumentation cable, armored power cable, flexible control cables, festoon cables, robotic cables and industrial data communications cables. These products have various applications in power generating stations and substations, process control, mining, material handling, machine tool and robotics markets.
Automotive Products. The Companys principal automotive products are ignition wire sets and booster cables for sale to the automotive aftermarket. Booster cable sales are affected by the severity of weather conditions and related promotional activity by retailers. As a result, a majority of booster cable sales occur between September and January.
The Company sells its automotive ignition wire sets and booster cables primarily to automotive parts retailers and distributors, hardware and home center retail chains and hardware distributors. The Companys automotive products are also sold on a private label basis to retailers and other automotive parts manufacturers.
Communications
The communications market consists of:
| | outside voice and data products wire and cable products for voice, data and video transmission applications; | |||
| | data communication products high-bandwidth twisted copper and fiber optic cables and multiconductor cables for customer premises, local area networks and telephone company central offices; | |||
| | electronics specialty products for use in machinery and instrumentation interconnection, audio, computer, security and other applications; and | |||
| | OEM products harnesses and assemblies for telecommunication, industrial and medical equipment manufacturers. | |||
Sales of communications wire and cable products in the global market have decreased significantly in recent years. This sales decline is the result of a significant decline in historic spending levels for outside plant telecommunications cables which has seen as much as a 50% decline from 1990s average spending and switching and local area network cables. Growth in this market will be largely dependent upon capital spending by the regional bell operating companies, or RBOCs, on maintenance, repair and expansion of their infrastructure and the level of information technology spending on network infrastructure. The Company believes the decline in sales has reached its bottom and that sales for communications wire and cable products will increase over time because current levels of spending by its communications wire and cable customers are insufficient to maintain their network infrastructures as surplus field inventories have been liquidated by the RBOCs.
Outside Voice and Data Products. The Companys principal outside voice and data products are outside plant telecommunications exchange cable and service wire. Outside plant telecommunications exchange cable is short haul trunk, feeder or distribution cable from a telephone companys central office to the subscriber premises. It consists of multiple paired conductors (ranging from 2 pairs to 4,200 pairs) and various types of sheathing, water-proofing, foil wraps and metal jacketing. Service wire is used to connect telephone subscriber premises to curbside distribution cable.
7
The Company sells its outside voice and data products primarily to telecommunications system operators through its direct sales force under supply contracts of varying lengths, and also to telecommunications distributors. The contracts do not guarantee a minimum level of sales. Product prices are generally subject to periodic adjustment based upon changes in the cost of copper and other factors.
Data Communications Products. Data communications products are high-bandwidth twisted pair copper and fiber optic cable for the customer premise, local area networks, central office and OEM telecommunications equipment markets. Customer premise products are used for wiring at subscriber premises, and include computer, riser rated and plenum rated wire and cable. Riser cable runs between floors and plenum cable runs in air spaces, primarily above ceilings in non-residential structures. Local area network cables run between computers along horizontal raceways and in backbones between servers. Central office products interconnect components within central office switching systems and public branch exchanges.
The Company sells data communications products primarily through distributors and agents. The fiber optic cable sold by the Company is manufactured by a joint venture company formed during 2002. The joint venture manufactures all of the Companys fiber optic cable products.
The market for data communications products has been adversely effected by a decrease in information technology spending. However, this decrease has been partially offset by continued spending in this market on maintenance and repair.
Electronics. Electronics products include multi-conductor, multi-pair, coaxial, hook-up, audio and microphone cables, speaker and television lead wire, and high temperature and shielded electronic wire. Primary uses for these products are various applications within the commercial, industrial instrumentation and control, and residential markets. These markets require a broad range of multi-conductor products for applications involving programmable controllers, robotics, process control and computer integrated manufacturing, sensors and test equipment, as well as cable for fire alarm, smoke detection, sprinkler control, entertainment and security systems.
OEM Products. Assemblies are used in communications switching systems and industrial control applications as well as medical equipment applications. These assemblies are used in such products as data processing equipment; telecommunications network switches, diagnostic imaging equipment, office machines and industrial machinery. The Companys industrial instrumentation and control products are sold primarily through distributors and agents.
Geographic Regions
General Cable operates its business in three main geographic regions: 1) North America, 2) Europe and 3) Oceania. The following table sets forth financial information by geographic region for the periods presented, in millions of dollars:
| Year Ended December 31, |
||||||||||||||||||||||||
| 2003 |
2002 |
2001 |
||||||||||||||||||||||
| Amount |
% |
Amount |
% |
Amount |
% |
|||||||||||||||||||
Net sales: |
||||||||||||||||||||||||
North America |
$ | 1,074.2 | 69 | % | $ | 1,077.2 | 74 | % | $ | 1,267.7 | 77 | % | ||||||||||||
Europe |
377.9 | 25 | % | 314.7 | 22 | % | 322.2 | 19 | % | |||||||||||||||
Oceania |
86.3 | 6 | % | 62.0 | 4 | % | 61.5 | 4 | % | |||||||||||||||
Total net sales |
$ | 1,538.4 | 100 | % | $ | 1,453.9 | 100 | % | $ | 1,651.4 | 100 | % | ||||||||||||
Operating income: |
||||||||||||||||||||||||
North America |
$ | 5.6 | 10 | % | $ | 15.0 | 31 | % | $ | 71.7 | 66 | % | ||||||||||||
Europe |
39.5 | 74 | % | 27.7 | 56 | % | 29.6 | 28 | % | |||||||||||||||
Oceania |
8.8 | 16 | % | 6.4 | 13 | % | 6.8 | 6 | % | |||||||||||||||
Subtotal |
53.9 | 100 | % | 49.1 | 100 | % | 108.1 | 100 | % | |||||||||||||||
Corporate charges |
(8.2 | ) | (33.4 | ) | (3.8 | ) | ||||||||||||||||||
Total operating income |
$ | 45.7 | $ | 15.7 | $ | 104.3 | ||||||||||||||||||
8
| December 31, |
||||||||
| 2003 |
2002 |
|||||||
Total long-lived assets: |
||||||||
North America |
$ | 219.0 | $ | 250.4 | ||||
Europe |
98.7 | 62.9 | ||||||
Oceania |
15.6 | 10.0 | ||||||
Total long-lived assets |
$ | 333.3 | $ | 323.3 | ||||
The Company believes that it is the largest participant in the North American market. The Companys European business is headquartered in Barcelona, Spain, and has three manufacturing facilities in the Barcelona area and a manufacturing facility near Lisbon, Portugal, all of which are supported by centralized marketing, sales and production planning. The main markets served are Spain, Portugal, France, United Kingdom, Norway, Belgium and Brazil, with approximately 75% of sales generated in the European market and the remaining 25% representing export sales. Over 90% of net sales in Europe and Oceania are derived from energy and industrial and specialty cable sales. The Companys Oceania business consists of a regional headquarters and manufacturing facility in Christchurch, New Zealand, a joint venture manufacturing facility in Fiji and sales offices in New Zealand and Australia. The business offers a broad product range in the energy, communications and electrical markets principally serving New Zealand, Australia, Fiji, and the Pacific Islands with certain products also sold into Asia.
Competition
The markets for all of the Companys products are highly competitive, and the Company experiences competition from several competitors within each market. The Company believes that it has developed strong customer relations as a result of its ability to supply customer needs across a broad range of products, its commitment to quality control and continuous improvement, its continuing investment in information technology, its emphasis on customer service, and its substantial product and distribution resources.
Although the primary competitive factors for the Companys products vary somewhat across the different product categories, the principal factors influencing competition are generally breadth of product line, inventory availability and delivery time, price, quality and customer service. Many of the Companys products are made to industry specifications, and are therefore essentially functionally interchangeable with those of competitors. However, the Company believes that significant opportunities exist to differentiate all of its products on the basis of quality, consistent availability, conformance to manufacturers specifications and customer service. Within some markets such as specialty and LAN cables, conformance to manufacturers specifications and technological superiority are also important competitive factors. Brand recognition is also a primary differentiating factor in the portable cord market and, to a lesser extent, in other product groups.
Raw Materials
The principal raw material used by General Cable in the manufacture of its wire and cable products is copper. The Company purchases copper in either cathode, rod or wire form from a number of major domestic and foreign producers, generally through annual supply contracts. Copper is available from many sources, and the Company believes that it is not dependent on any single supplier of copper. In 2003, the Companys two largest suppliers of copper accounted for approximately 35% and 33% of its North American copper purchases.
The Company has centralized its copper purchasing in North America to capitalize on economies of scale and to facilitate the negotiation of favorable purchase terms from suppliers. The cost of copper has been subject to considerable volatility over the past several years. However, as a result of a number of practices intended to match copper purchases with sales, the Companys profitability has generally not been significantly affected by changes in copper prices. The Company generally passes changes in copper prices along to its customers, although there are timing delays of varying lengths depending upon the volatility in copper prices, the type of product, competitive conditions and particular customer arrangements. The Company does not engage in speculative metals trading or other speculative activities, nor does it engage in activities to hedge the underlying value of copper inventory.
Other raw materials utilized by the Company include aluminum, nylon, polyethylene resin and compounds and plasticizers, fluoropolymer compounds, fiber and a variety of filling, binding and sheathing materials. In 2003, the Company produced approximately 62% and 61% of its bare wire strand and PVC compound requirements for its North American operations. The Company believes that all of these materials are available in sufficient quantities through purchases in the open market.
Patents and Trademarks
The Company believes that the success of its business depends more on the technical competence, creativity and marketing abilities of its employees than on any individual patent, trademark or copyright. Nevertheless, the Company has a policy of seeking patents when
9
appropriate on inventions concerning new products and product improvements as part of its ongoing research, development and manufacturing activities.
The Company owns a number of U.S. and foreign patents and has patent applications pending in the U.S. and abroad. The Company also owns a number of U.S. and foreign registered trademarks and has many applications for new registrations pending.
Although in the aggregate these patents and trademarks are of considerable importance to the manufacturing and marketing of many of the Companys products, it does not consider any single patent or trademark or group of patents or trademarks to be material to its business as a whole. While the Company occasionally obtains patent licenses from third parties, none are deemed to be material. Trademarks which are considered to be generally important are General Cable®, Anaconda®, BICC® and Carol®, and the Companys triad symbol. The Company believes that its products bearing these trademarks have achieved significant brand recognition within the industry.
The Company also relies on trade secret protection for its confidential and proprietary information. The Company routinely enters into confidentiality agreements with its employees. There can be no assurance, however, that others will not independently obtain similar information and techniques or otherwise gain access to the Companys trade secrets or that the Company will be able to effectively protect its trade secrets.
Environmental Matters
The Company is subject to a variety of federal, state, local and foreign laws and regulations covering the storage, handling, emission and discharge of materials into the environment, including CERCLA, the Clean Water Act, the Clean Air Act (including the 1990 amendments) and the Resource Conservation and Recovery Act.
The Companys subsidiaries in the United States have been identified as potentially responsible parties with respect to several sites designated for cleanup under CERCLA or similar state laws, which impose liability for cleanup of certain waste sites and for related natural resource damages without regard to fault or the legality of waste generation or disposal. Persons liable for such costs and damages generally include the site owner or operator and persons that disposed or arranged for the disposal of hazardous substances found at those sites. Although CERCLA imposes joint and several liability on all potentially responsible parties, in application, the potentially responsible parties typically allocate the investigation and cleanup costs based upon, among other things, the volume of waste contributed by each potentially responsible party.
Settlements can often be achieved through negotiations with the appropriate environmental agency or the other potentially responsible parties. Potentially responsible parties that contributed small amounts of waste (typically less than 1% of the waste) are often given the opportunity to settle as deminimus parties, resolving their liability for a particular site. The Company does not own or operate any of the waste sites with respect to which it has been named as a potentially responsible party by the government. Based on the Companys review and other factors, it believes that costs to the Company relating to environmental clean-up at these sites will not have a material adverse effect on its results of operations, cash flows or financial position.
In the transaction with Wassall PLC in 1994, American Premier Underwriters, Inc. agreed to indemnify the Company against liabilities (including all environmental liabilities) arising out of the Companys or the Companys predecessors ownership or operation of the Indiana Steel & Wire Company and Marathon Manufacturing Holdings, Inc. businesses (which were divested by the predecessor prior to the 1994 Wassall transaction), without limitation as to time or amount. American Premier also agreed to indemnify the Company against 66 2/3% of all other environmental liabilities arising out of the Companys or the Companys predecessors ownership or operation of other properties and assets in excess of $10 million but not in excess of $33 million, which were identified during the seven-year period ended June 2001. Indemnifiable environmental liabilities through June 2001 were substantially below that threshold. In addition, the Company also has claims against third parties with respect to some of these liabilities.
During 1999, the Company acquired the worldwide energy cable and cable systems business of Balfour Beatty plc, previously known as BICC plc. As part of this acquisition, the seller agreed to indemnify the Company against environmental liabilities existing at the date of the closing of the purchase of the business. The indemnity is for an eight-year period ending in 2007, while the Company operates the businesses, subject to certain sharing of losses (with BICC plc covering 95% of losses in the first three years, 80% in years four and five and 60% in the remaining three years). The indemnity is also subject to the overall indemnity limit of $150 million, which applies to all warranty and indemnity claims in the transaction. In addition, BICC plc assumed responsibility for cleanup of certain specific conditions at various sites operated by the Company and cleanup is mostly complete at these sites. In the sale of the businesses to Pirelli in August 2000, the Company generally indemnified Pirelli against any environmental liabilities on the same basis as BICC plc indemnified it in the earlier acquisition. However, the indemnity the Company received from BICC plc relating to the European businesses sold to Pirelli terminated upon the sale of those businesses to Pirelli. In addition, the Company generally indemnified Pirelli against other claims relating to the prior operation of the business. Pirelli
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has asserted claims under this indemnification. The Company is continuing to investigate these claims and believes that the reserves currently included in the Companys balance sheet are adequate to cover any obligations it may have.
General Cable has agreed to indemnify Raychem HTS Canada, Inc. against certain environmental liabilities arising out of the operation of the business it sold to Raychem HTS Canada, Inc. prior to its sale. The indemnity generally is for a five year period from the closing of the sale and is subject to an overall limit of $60 million. At this time, there are no claims outstanding under this indemnity.
General Cable has also agreed to indemnify Southwire Company against certain environmental liabilities arising out of the operation of the business it sold to Southwire prior to its sale. The indemnity is for a ten year period from the closing of the sale and is subject to an overall limit of $20 million. At this time, there are no claims outstanding under this indemnity.
While it is difficult to estimate future environmental liabilities accurately, the Company does not currently anticipate any material adverse effect on its results of operations, financial condition or cash flows as a result of compliance with federal, state, local or foreign environmental laws or regulations or cleanup costs of the sites discussed above.
Employees
At December 31, 2003, approximately 6,000 persons were employed by General Cable, and collective bargaining agreements covered approximately 3,600 employees at various locations around the world. During the last five years, the Company has experienced one strike in Oceania which was settled on satisfactory terms. There have been no other major strikes at any of the Companys facilities during the last five years. In North America, union contracts will expire at six facilities in 2004 and three in 2005. In Europe and Oceania, labor agreements are generally negotiated on an annual or bi-annual basis. The Company believes that its relationships with its employees are good.
Item 2. Properties
The Companys principal properties are listed below. The Company believes that its properties are generally well maintained and are adequate for the Companys current level of operations.
| Owned | ||||||||
| Square | Use/Product | or | ||||||
| Location |
Feet |
Line(s) |
Leased |
|||||
North America |
||||||||
Manufacturing Facilities: |
||||||||
Marion, IN(1)
|
745,000 | Industrial & specialty cables | Owned | |||||
Marshall, TX
|
692,000 | Aluminum low-voltage energy cables | Owned | |||||
Willimantic, CT
|
686,000 | Industrial & specialty cables | Owned | |||||
Manchester, NH
|
550,000 | Electronic products | Owned | |||||
Lawrenceburg, KY
|
383,000 | Outside voice and data products and data communications products | Owned | |||||
Bonham, TX
|
364,000 | Outside voice and data products | Owned | |||||
Lincoln, RI
|
350,000 | Industrial & specialty cables and automotive products | Owned | |||||
Malvern, AR
|
338,000 | Aluminum medium-voltage energy cables | Owned | |||||
DuQuoin, IL
|
279,000 | Medium-voltage energy cables | Owned | |||||
Tetla, Mexico
|
218,000 | Outside voice and data products | Owned | |||||
Altoona, PA
|
193,000 | Automotive products | Owned | |||||
Jackson, TN
|
182,000 | Data communications cables | Owned | |||||
South Hadley, MA(2)
|
150,000 | Bare wire fabricating | Owned | |||||
LaMalbaie, Canada
|
120,000 | Low-and medium-voltage energy cables | Owned | |||||
St. Jerome, Canada
|
110,000 | Low-and medium-voltage energy cables | Owned | |||||
Distribution and Other Facilities: |
||||||||
Lebanon, IN
|
198,000 | Distribution center | Leased | |||||
Chino, CA
|
189,000 | Distribution center | Leased | |||||
Highland Heights, KY
|
166,000 | World headquarters, technology center and learning center | Owned | |||||
Plano, TX
|
60,000 | Rod mill | Owned | |||||
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| Owned | ||||||||
| Square | Use/Product | or | ||||||
| Location |
Feet |
Line(s) |
Leased |
|||||
Barcelona, Spain(3)
|
1,080,000 | Power transmission and distribution, industrial & specialty cables | Owned | |||||
New Zealand(3)
|
314,000 | Power distribution, industrial & specialty and communications cables | Owned | |||||
Lisbon, Portugal
|
255,000 | Power distribution, industrial & specialty and communications cables | Owned | |||||
| (1) | The Company is in the process of significantly reducing operations at this facility. | |||
| (2) | The Company has initiated a feasibility study to determine whether to continue operations at this facility. | |||
| (3) | Certain locations represent a collection of facilities in the local area. | |||
Item 3. Legal Proceedings
General Cable is subject to numerous federal, state, local and foreign laws and regulations relating to the storage, handling, emission and discharge of materials into the environment, including CERCLA, the Clean Water Act, the Clean Air Act (including the 1990 amendments) and the Resource Conservation and Recovery Act.
General Cable subsidiaries have been identified as potentially responsible parties with respect to several sites designated for cleanup under CERCLA or similar state laws, which impose liability for cleanup of certain waste sites and for related natural resource damages without regard to fault or the legality of waste generation or disposal. General Cable does not own or operate any of the waste sites with respect to which it has been named as a potentially responsible party by the government. Based on its review and other factors, management believes that costs relating to environmental clean-up at these sites will not have a material adverse effect on the Companys results of operations, cash flows or financial position.