Rich Harshman
Analyst · Cowen and Company. Please go ahead
Thank you, Pat. Turning to slide 7, the aerospace and defense market continues to be our largest end market. ATI's sales into the aerospace and defense market for 2014 were $1.45 billion representing 34% of sales. We expect that the commercial aerospace market will be a significant driver of our profitable growth over the next 5 years, as production rates ramp for the next generation engine programs and airframe OEMs produce their record backlogs. Fourth quarter 2014 sales to the aerospace and defense markets were flat compared to the third quarter 2014. While sales for our specialty materials mill products decreased 3%, sales of our forgings increased 6% and sales of our titanium investment castings increased 3%, all compared to the third quarter 2014. High Performance Materials and Components segment titanium mill product shipments decreased 22% compared to the third quarter 2014. During the third quarter, titanium ingot shipments for airframe applications were unusually strong. Looking at shipments for the full year 2014 compared to 2013, titanium mill product shipments increased 9% and nickel-based and specialty steel alloy increased 11%. During 2014 and so far early in 2015, ATI reached agreement on several strategic LTAs with aerospace OEMs that total over $4 billion in expected revenue. These LTAs are for ATI's specialty materials mill products, forgings and investment castings required for both next-generation and legacy platforms. These LTAs support our profitable growth in the aerospace market over the next 5 years and into the next decade. Most of these LTAs continue a trend of being more strategic with a longer term. A trend that we have seen for the past few years. Our current shipset set values for key next-generation airframes and their engines are estimated as follows. The Boeing 737MAX $1.1 million per shipset, that's twice the value compared to the current content on the legacy 737. The Boeing 787 $2.8 million content. And Airbus A350 $1.5 million content per shipsets. We continue to pursue additional LTAs and development opportunities on these programs and the future generation of airplanes and engines, which are expected to enter into service late this decade and beyond. With our focus on creating value through relentless innovation, we have secured important strategic positions on next-generation engines. And with our technology, diversified products and advanced and integrated manufacturing capabilities, we are well positioned to work directly with the OEMs on the development of future generation technologies and products. Turning to slide 8, shown is the most recent forecast of commercial aircraft build rates. The black line on this chart represents the number of next-generation airplanes and the build rate forecast. This black line is a good proxy for ATI's potential aerospace market growth trajectory, since we have secured increased positions on many of the next-generation airplanes and engines that power them. Slide 9 shows the firm order backlog of the major engine programs, which as of November 30, 2014, the latest data available, stands at over 21,700 large jet engines. The first 5 lines show the backlog for engines with power single-aisle airplanes. As expected, the trend in 2014 has been a declining backlog for the legacy engines, shown in the first 3 lines of the chart, with an increase in backlog for next-generation engines. Note the CFM LEAP backlog is now over 8000 engines. The single-aisle engine is the high-volume engine. Enhancing ATI's position in this category on both the CFM LEAP and the PW 1000 is an accomplishment that we have focused on and have been working toward for several years. Moving to slide 10, the oil and gas chemical process industry market is our second largest end market. ATI's sales into this market for 2014 were $752 million, representing 18% of sales. 10% to oil and gas and 8% to the chemical process industry. Total sales to this market in the fourth quarter of 2014 increased 14% compared to the third quarter 2014. Oil and gas sales alone increased by 30% primarily due to initial shipments for the large nickel-based alloy plate order we received for use in a sour gas pipeline. Shipments for this project are expected to continue through the first half of 2015. For our market update, first, recent significant declines in oil price creates uncertainty in future demand for a relatively small portion of ATI's products, especially for the second half of 2015. Second, except for drilling, we are not currently seeing much change in demand and have a strong backlog for our oil and gas products through the first half of 2015. To put this into perspective, ATI's sales for drilling applications represented approximately $150 million of total 2014 sales, or about 3.5% of total sales. We currently expect sales for drilling applications to be 20% to 25% lower in 2015 than in 2014, which represents a potential decrease of less than $40 million in revenue. Third, our oil and gas customers are cautious and are closely monitoring their inventory due to this uncertainty, and we will monitor this market very closely as well. ATI's' strength of diversity in oil and gas products that is downhill – down hole drilling and completions coupled with upstream offshore and downstream petrochemical give us some insulation against short-term shifts in exploration and production capital spending. The offshore segment maintains longer term spend strategies while the downstream segment takes advantage of lower cost feedstocks. For ATI, oil and gas is a global market which includes very large offshore and onshore products that require our corrosion-resistant alloys that can safely operate at high temperatures and high pressures. These multi-billion dollar project projects take years to complete. Further helping to diversify this market segment is our participation in the chemical process industry. The oil and gas and CPI markets are often countercyclical to each other, as lower oil and gas prices can be a positive development for the CPI market. At this time, we're not seeing any planned chemical projects in the US being canceled and large North American LNG projects are moving forward. Another strength of ATI is the diversification of products that we provide to the oil and gas and chemical process industry markets. We continue to expand our product offerings to these markets. The HRPF gives us the capability to offer the market larger and flatter coils of nickel-based alloys, duplex alloys and other specialty alloys and stainless alloys. We are also expanding our forged products position in this market. ATI flowform products is being evaluated for many new applications. Oil and gas and chemical process industry is a target market for our flowform products and has the potential for significant growth as a replacement for products that we currently do not make. Turning to slide 11, the product commissioning of our HRPF was completed during the fourth quarter 2014. This commissioning effort, which began in the second quarter of 2014, went exceptionally well given our diverse Flat Rolled product mix. Approximately 97% of all coils processed during commissioning met customer specification which included first-time runs for all of our alloy systems. Our ATI Flat Rolled products team did an outstanding job throughout this challenging process. As expected the HRPF has proven to be a game changing investment designed to significantly enhance ATI's Flat Rolled product capabilities and reduce manufacturing cycle times for all of our Flat Rolled products. The HRPF investment enables us to reengineer our Flat Rolled products business with a renewed focus on shorter manufacturing cycle times and an improved and much more competitive cost structure. We are only at the beginning of capturing the full benefits of this facility. Our people are embracing the new technology, successfully producing thinner and flatter coils that dramatically improve productivity and operating practices and reduce costs at our finishing plants as well as at our rolling facility. The HRPF is designed to provide broader customer appeal since we can now make wider, longer and flatter coils and alloy systems outside the reach of our 2 legacy hot mills. Our customers like our new and enhanced product capabilities which add to our industry-leading technical capabilities and customer service. We have agreements in place that provide increased participation, add existing customers and significant share gains with new customers. We offer a wider range of products than in the past permitting us to bid on packages previously out of our reach. 48-inch wide nickel-based alloy sheet expands our presence in the global aerospace and oil and gas chemical process industry markets. 60-inch wide stainless coils expand our reach into new and existing service center customers. We expect to grow in the strong North American automotive market with agreements in place for auto exhaust applications as well as continued growth in the global automotive market as a result of agreements in place for our precision rolled strip products for alloys ranging from specialty stainless to nickel-based alloys. Finally, customers tell us they like our shorter lead times that result from faster flow times and reduce raw materials risk, improve inventory turns and increase cash flow. As a result beginning in 2015, we expect increased shipments and a significantly improved product mix and the beginning of a better cost structure in our Flat Rolled products segment. We expect to see gradual improvement in Flat Rolled products segment operating profit beginning of the second quarter 2015 as volumes increase and startup costs abate. We are forecasting approximately $5 million in startup costs relating to the HRPF during the first quarter 2015. And the legacy hot mills are scheduled to be shut down by the end of the first quarter of 2015. This is expected to result in a significant cost reduction and improve production efficiencies. We expect to realize the sales growth in cost reduction benefits as we increase production volume during 2015. As previously stated, we expect fourth quarter 2015 operating profit to benefit at an annualized run rate of $150 million compared to 2014, which includes the elimination of startup costs. We believe that the HRPF investment in combination with our unsurpassed finishing capabilities and our continued focus on cost reduction and enhancing our market position for both standard grade and high-value Flat Rolled products enables the successful transformation of our Flat Rolled products business into a global leader that can sustain profitable growth through business cycles. Our goal is to ensure that our Flat Rolled products business can be profitable even in weak markets and can average after-tax returns on capital employed greater than ATI's cost of capital through a business cycle. By achieving this objective, our Flat Rolled products business will create value for our shareholders and customers and provide opportunities for our employees. During the fourth quarter, our Rowley facility achieved approval by a major OEM as a premium quality, or PQ, titanium sponge supply. We expect to achieve process and product approval during the first half of 2015, which is ahead of our original schedule. The ramp up process at Rowley has begun. We plan to move from the current capacity utilization rate of approximately 50% to optimum levels by the end of 2015. We will be able to use the Rowley sponge for premium quality products this year. However, operating results will continue to be negatively impacted until Rowley's capacity utilization improves to optimal levels. In our High Performance Materials and Components segment, we are seeing signs that aerospace market demand for our product is becoming aligned with the airframe and jet engine build rates as destocking runs its course. In our Flat Rolled products segment, we expect improved volume and better product mix in 2015 as we begin to realize the full range of capabilities of the HRPF. As I stated earlier, startup costs of approximately $5 million are expected to be incurred in the first quarter 2015 as we transition to full production and idle the existing legacy hot rolling assets in our Flat Rolled products segment. We expect PQ titanium sponge qualification cost to impact first half 2015 operating profit. And costs attributable to production inefficiencies to impact the full year 2015 as the sponge is used and produced into mill products. Costs are expected to improve in the second half of 2015 until optimum production levels are achieved by year end. We currently expect approximately $7 million of titanium sponge qualification costs in the first quarter of 2015 with a similar amount likely in the second quarter of 2015. We expect these costs to be lower through the second half as production ramps increase. We currently expect 2015 pretax retirement benefit expense to be about $78 million, a decrease of $18.2 million compared to 2014 excluding the $25.5 million curtailment and settlement gain recorded in the fourth quarter of 2014. Most of the 2015 pension expense is expected to be non cash. We're currently forecasting 2015 capital expenditures at approximately $290 million, approximately 50% of which is primarily related to the completion of payments associated with the HRPF project and final acceptance testing of the equipment. Depreciation and amortization expense in 2015 is forecasted to be approximately $196 million. So in summary, drivers of our secular growth markets remain intact. While we are concerned about demand from the oil and gas market due to the recent significant declines in oil prices, we believe that our risk in this market is manageable and can be mitigated by our diversification and by potential growth in the chemical process industry and by our new product offerings. Our extraordinary capital expenditure cycle is nearly behind us. The HRPF is in commercial operation. We expect to begin realizing top and bottom line benefits from this game changing asset beginning in 2015. Our Rowley, Utah facility is approved as a PQ titanium sponge supplier by a leading jet engine OEM. Process and product qualification is ahead of schedule and is expected to be achieved in the first half of 2015. We have been awarded over $4 billion in strategic LTAs that secure significant growth for ATI on legacy and next-generation airplanes and their jet engines. This growth is expected to provide significant profitable growth opportunities for ATI specialty materials mill products, forgings and investment castings over the next 5 years. As always we face numerous markets challenges and we must execute. Our challenge and our opportunity is to execute our business strategies and turn the enabling technology and capabilities of the HRPF, the Rowley investment and other strategic investments we've made over the past several years, into value creators for our shareholders and customers. The HRPF combined with lean manufacturing cost reduction and continuous improvement initiatives in our Flat Rolled products business are keys to this business being a contributor to ATI's' profitable growth. We look forward to solving these challenges and delivering on the opportunities. Operator, may we have the first question please?