Philip Horlock
Analyst · Craig-Hallum
Well, thanks, Jeff. Good afternoon, and thank you, all, joining us today for our second quarter earnings call. We welcome this opportunity to take you through our latest quarter results. But first, I'd like to start by giving a sense of the winning culture we are building at Blue Bird, and importantly, what we stand for at Blue Bird.
So let's turn to Slide 4. We start with our experienced school bus team, where our employees have an average of 14 years of employment with us. In fact, when you exclude the new employees we've hired over the last 3 years, our average tenure is almost 20 years. That's best in industry experience in making school buses. We constantly challenge ourselves to drive the business forward and seize opportunities to improve and win in the market, while demanding innovation throughout all activities to provide Blue Bird with competitive advantages that customers want and they value. And we reward these behaviors through our management compensation process. The fact that we have the broadest array of products with many features that are exclusive to us in the industry and have been the fastest growing school bus company over the past few years are outcomes are the winning culture we are building. What we stand for is straightforward: to design, build, sell and service the world's finest school bus. Unique among the school -- the major school bus OEMs, we're exclusively focused on the school bus business, from our purpose-built chassis and body designs and right through our dealer network. This focus resonates with our customers, where in a recent blind survey that we commissioned, Transportation Direct has ranked Blue Bird #1 in our 4 priorities: safety, quality, durability and serviceability. We are proud of that fact, and we'll continue to have drive to win in the marketplace.
So let's now look at our second quarter highlights on Slide 5. It's been an eventful second quarter at Blue Bird with a lot of positives. Our net sales were about 4% above last year. And although not shown on this slide, our unit sales of 2,132 buses in the second quarter were 2% higher than a year ago, and importantly, more than 50% higher than our sales in the first quarter. Our propane bus momentum continues to be very strong, with unit sales up 20% from the same period last year. And through the first half of the year, our propane bus unit sales were up a substantial 46% from a year ago. Now we'll be discussing our propane performance in a little more detail a bit later.
We're continuing to see strong quarter activities through our dealer network, providing us with a solid pipeline of potential future orders, had a successful bid confirmed into a firm order in a matter of days or several months later, as school board released funds for bus purchases to support school start. Because of our strong pipeline, I can tell you now that our third quarter production slots are completely filled with firm, noncancelable orders, covering the period April through June, and unit sales will be about 20% above last year's third quarter.
Now to support our expected second half surge in volume and to align our production capacity with a seasonal customer demand, we successfully launched our second shift this past quarter. We'll be hiring about 200 full-time associates this year, and today, we are scheduling and building 64 buses a day compared with our peak capacity last year of 42 buses a day. We'll continue to ramp up our capacity, and we'll reach 70 buses a day by the end of June, ensuring we can meet the important school start dates for new bus deliveries.
We're committed to providing innovative and differentiated products that customers want and value. And to this end, we're progressing toward the launch of 4 exciting and brand-new powertrains this year. We are the first and only manufacturer to operate a gasoline-powered bus in the large school bus segment, and I'll cover this in more detail later. Our all new CNG-powered Blue Bird Vision bus provides a lower priced Type C bus option to go with today's CNG-powered Type C bus option. Both of these engines are from our exclusive partnership with Ford and ROUSH CleanTech, deploying Ford’s modern 6.8-liter V10 engine, and fuel systems developed uniquely by the ROUSH team, just for us. In fact, along with our class-leading propane offering, we will have 3 distinct powertrains using the same Ford engine and transmission architecture. Now this is great news for the mechanics and service techs who work on those engines.
Next, we'll be first to market with Cummins' all new 5 liter V8 diesel, which is a new, lighter-weight engine offered at a lower acquisition price than any other diesel option, while delivering a pure -- improved fuel economy.
Last, our new Eaton Procision Transmission option will be available on most diesel engines this year and is the first dual clutch, 7-speed automatic available on school buses in North America. It provides efficient acceleration, optimized shift points and improved fuel economy and a host of features that make the bus easy to drive.
To showcase these and other new products and features, we held 2 live and drive events in Dallas and Nashville this past quarter, with all of our dealers and many of the customers in attendance. I can tell you the responses were outstanding, and there's real excitement about these all-new product set in the marketplace.
On the personnel front, we brought onboard a new Chief Commercial Officer this month. Mark Terry joined us from our Dealer of the Year winner, Yancey Bus Sales of Georgia, where he was a General Manager, bringing great dealer experience into the Blue Bird family. Mark also has extensive experience at Caterpillar and is a great add to our Blue Bird leadership team. Dale Wendell has been running our sales and marketing activities for the past 5 years, and will be retiring end of this month. We wish Dale all the best in the future, and thank him for his drive and key accomplishments in growing Blue Bird sales in each of the past 5 years. Thanks, Dale, for a great job done.
So it was a busy and eventful second quarter for Blue Bird. And with solid financial results in line with our expectations, our third quarter production slots filled and a strong pipeline for new orders, we are reaffirming our full year guidance for sales, profitability and free cash flow.
So let's now take a closer look at our second quarter financial results on Slide 6. Second quarter net sales of $191.2 million was $8.2 million or 4% higher than the same period last year, and both booked sales and parts sales grew by about 4% in the second quarter. At $10.1 million, we recorded a solid adjusted EBITDA, which is slightly up higher than a year ago, and included higher engineering and support costs required to deliver our new powertrain initiatives.
Through the first half of the year, net sales are down about 7.5%, as we've seen customers continue to shift order timing and bus deliveries to later in the year. Now a 20% growth in firm production orders in hand for the third quarter is evidence of this shift in order timing, and we are well positioned from a production capacity standpoint to accommodate customers’ second half needs and ensure our buses are delivered in time to meet school start.
Turning now to Slide 7, let's take a closer look at our propane bus sales performance. Blue Bird's propane-powered Vision bus continues to be our #1 product differentiator in the marketplace, and we are the undisputed sales leader with 9x more propane buses registered and on the road today than all of our competitors combined. Now that's leadership. Our propane Vision bus also registers the highest owner loyalty in the industry. Our first half propane bus unit sales were up a substantial 46% compared with last year. And year-to-date, more than 40% of our customers are new to propane. Furthermore, 18% of our unit sales in the first half were propane buses, up from 11% mix last year. These are significant results that we're very pleased with. The advantages of propane over other fuels are clearly understood, and market sectors is growing, as customer testimonials confirm the total cost of ownership and other key benefits. As a reminder, our proven, modern efficient propane engine is exclusive to Blue Bird, and developed and supported by our partnership with Ford and ROUSH CleanTech.
At Blue Bird, we believe in being first to market with differentiated products, and where we can, we strive for exclusivity. And our propane success is a great example of this.
So let's now turn to Slide 8 to look at another great example of an exclusive and innovative new product launching in fiscal '16 that’s important to our continued growth. We are the first and only manufacturer to offer gasoline-powered bus in the large school bus segment. Mechanics and technicians understand gasoline engines. They're simpler to maintain, servicing costs are lower and they perform exceptionally well in cold climate conditions. As I mentioned earlier, this bus will utilize the same proven engine transmission used in our propane-powered bus and is another product from our exclusive partnership with Ford and ROUSH CleanTech. The bus will be a great choice for customers who want the lowest acquisition price of any fuel type and simpler maintenance for their technicians. We've had terrific interest from customers since we announced this engine is coming in 2016. Incoming orders are strong, and we'll begin shipping buses to customers in our fiscal fourth quarter, again in time to meet school start. We're excited about the growth potential for our gasoline-powered bus, which builds on the success we've achieved with our propane products.
Now I'm going to turn it over to Phil Tighe, who'll cover our financial results. Phil?