Razvan Radulescu
Analyst · Craig-Hallum. Please go ahead
Thanks, Matt and good afternoon. It’s my pleasure to share with you the financial highlights from Blue Bird’s fiscal 2022 and fourth quarter results. The quarter end is based on a closed date of October 1, 2022, whereas the prior year was based on a closed date of October 2, 2021. We will file the 10-K today December 12 after the market closes. Our 10-K includes additional material and disclosures regarding our business and financial performance. We encourage you to read the 10-K and the important disclosures that it contains. The appendix attached to today’s presentation includes reconciliations of differences between GAAP and non-GAAP measures mentioned on this call as well as important disclaimers. Slide 11 is a summary of fourth quarter and full year results for fiscal ‘22. I will start with the fourth quarter results summary and I will focus on the full year results for fiscal ‘22 and guidance for fiscal ‘23 for the remaining of the presentation. It was another challenging quarter for Blue Bird with some persistent supply chain disruptions limiting our throughput and impacting our efficiency and over time with the planned and delayed inflationary cost pressures that became effective on July 1. We also had extremely high working process at the beginning of the quarter and we worked through still a large number of all backlog low margin units with older pricing. Despite all these challenges, the team has done a fantastic job and generated 2016 unit sales volume, which was 105 units or 6% higher than prior year. Consolidated net revenue of $258 million was $66 million or 34% higher than prior year, driven primarily by higher mix of electric buses and pricing actions that are starting to take hold. The adjusted free cash flow was $30 million positive, $70 million higher than the prior year fourth quarter. This outstanding performance was driven by the reduction in inventory back to normal levels during the quarter and supports our great liquidity position at the end of fiscal ‘22. Adjusted EBITDA for the quarter was negative $16 million and it includes a non-cash inventory charge of negative $9 million, which we took at the end of the year. Excluding this charge, the adjusted EBITDA would have been negative $7 million due to supply chain driven operational inefficiencies that were incurred in working down the inventory. Additionally, we experienced in this quarter increased material costs and still a relatively large amount of all backlog units. Looking back at the total year, fiscal ‘22 was an incredibly difficult year for Blue Bird. We started in Q1 with the supplier allocation that cut our volumes approximately in half, followed by unprecedented inflation in steel prices that almost tripled by Q2. We had fixed pricing on all backlog during the entire first half and an unsuccessful production increase in Q3 and the respective inventory accumulation. However, the current trends are encouraging, with all the operational metrics starting to improve during Q3 and continuing in Q4. As a result, we sold 6,822 buses in the year, 143 units higher than prior year, so slightly above fiscal ‘21. Consolidated net revenue of $801 million was $117 million or 17% higher than prior year, driven by pricing actions that started to take hold, especially in the second half of fiscal ‘22. The adjusted free cash flow was negative $23 million and still $39 million higher than the prior year, driven by the reduction in inventory back to normal levels by the end of Q4. Adjusted EBITDA was negative $15 million or $49 million below prior year. This includes a year-end $9 million non-cash inventory charge. Excluding that, the adjusted EBITDA for the year would have been negative $6 million. Moving on to Slide 12. As mentioned before by Matt, our backlog at the end of the year continues to be extremely strong at over 5,000 units with the vast majority of these units at much higher price levels compared to the fiscal ‘22 build units, more on this later on. Breaking down the $801 million in revenues into our two business segments, the bus net revenue was $724 million, up by almost $100 million versus prior year. Our average bus revenue per unit increased from $94,000 to $106,000, which was largely the result of pricing actions taken over the past 12 months as well as a higher mix of electric buses, 3.9% versus 2.2%. Supply-constrained EV sales were at a level of 269 units or 123 more than last year, an 84% increase. Parts revenue for the year was $77 million, representing an improvement of $18 million or 30% compared to the prior year. Over the past few quarters, we have seen improvement in part sales, which is an indicator that the normal workforce school district is getting back to pre-COVID levels. Gross margin for the year was 4.6% or 590 basis points lower than last year due to the old backlog fixed pricing, increased material costs and supply-driven operational inefficiencies. In fiscal ‘22, adjusted net income was negative $36 million or $45 million lower than last year. Adjusted EBITDA of approximately negative $15 million was down compared with prior year by $49 million. Adjusted diluted earnings per share of negative $1.15, was down $1.46 from the prior year. Slide 13 shows the walk from fiscal ‘21 adjusted EBITDA to the fiscal ‘22 results. Starting on the left of $34 million, slightly higher bus volume of 143 units and increased parts margins generated a positive $8 million improvement year-over-year. The next three bars need to be analyzed together. Pricing improvements of approximately 10% lifted our standard gross margin by $80 million. However, the material costs, including steel increased by $72 million year-over-year and supply chain disruptions and higher freight costs generated operating inefficiencies of $51 million. Bottom line, due to the old backlog and fixed pricing, we’re able to cover only two-thirds of the extra costs incurred during the year. SG&A and engineering expenses, excluding restructuring expenses, were each $4 million higher than last year due to labor cost increases versus extraordinary COVID related cuts in prior year and Blue Bird reinvesting in engineering projects to ensure our future growth in EV and chassis and to maintain our leading product competitiveness. Additionally, our JV results from Micro Bird were close to $5 million lower versus prior year, but they have been also affected by supply chain shortages, predominantly the Microchip shortage, which is impacting the chassis allocation from Ford and GM. As of today, the chassis supply has been improving, and we expect the JV to return to profitability in fiscal year ‘23. Looking at the total year results. If you add back the operational inefficiencies driven by the supply chain of $51 million and the year-end non-cash inventory charge of $9 million, our results have been $45 million or $11 million improvement versus the prior year. Moving on to Slide 14. We have all across the board positive development year-over-year on the balance sheet. We ended the year roughly with $10 million in cash and reduced our debt by almost $40 million. The improvement in operating cash flow and adjusted free cash flow were primarily driven by trade working capital due to our inventory reduction in the last quarter. I will discuss this more on the next slide. As a subsequent event, at the end of November, we entered into the 6th amendment to our credit facility, extending the maturity date through December 31, 2024. The 6th amendment provides for revised covenants, modifications to the revolving credit facility and the new pricing grid. The amended covenants and the extended maturity of our loan provides Blue Bird with both flexibility and stability as our business continues to recover from the COVID-19 pandemic and associated global supply chain disruptions. On Slide 15, you’ll see the fantastic progress done by our operations team to reduce raw material inventories and work in process, returning to a normal level by the end of the quarter, as indicated in our last earnings call. As a reminder, our end of Q3 inventory levels were elevated due to the unsuccessful steel production ramp-up we kicked off before the war in Ukraine and China lockdowns happened earlier in the year. As mentioned before in the presentation, at the end of Q4, certain robust segment inventory had an approximately $8.8 million cumulative cost in excess of net realizable value that was recognized as a loss in fiscal ‘22 with no similar activity in fiscal ‘21. We are also continuing our strategic pre-buy of major components Ford engines and EV components to ensure smooth production levels in fiscal ‘23. We are very happy to report that the positive inventory reduction trend continued through October and November in fiscal ‘23, Q1. And our liquidity sits at approximately $100 million as of December 1, with the revolver balance at zero. So our balance sheet is in great shape for fiscal ‘23. In the next few slides, we will share with you why we are very confident that the worst is behind us. Our turnaround is working, and we are on track to return Blue Bird to historical profitability during fiscal ‘23. On Slide 16, you see how after the steel spot prices shot back up $300 to $500 per ton in March and April that bubble reversed itself by July. The favorable trend continued through December 1, and this is a very good development for our future results, especially for second half of fiscal ‘23 and into fiscal ‘24. One is to take into account that we are also entering in future logged contracts for steel prices with certain tonnages up to 12 months forward. Therefore, the favorable impact will be a stair-step function of blending lock tonnages with superior spot prices. However, this is an upside at this point for our fiscal ‘23 results, assuming that spot prices remained relatively low in the future. On Slide 17, we are showing a simplified production versus backlog age and pricing structure as an update of how we are working through the backlog with old pricing. You can see that the first half of fiscal ‘22 was comprised entirely of all backlog units. By Q3 and into Q4, we started to build some better-priced units, but still with the gap versus the current economics. This explains a large portion of our losses during fiscal ‘22. Together with our dealer partners, we also were able to increase partially the prices for backlog units beginning with May production and recovered above half of the missing pricing for each respective price level. However, during fiscal ‘23, Q1, we still have approximately one-third of our production with very old units and some of the worst margins. We estimate this headwind to be approximately $10 million for fiscal ‘23, Q1 or 5% on approximately $200 million in revenues. Nevertheless, starting with fiscal ‘23, Q2 in January, we will have put the vast majority of the all backlog units behind us and have locked in pricing and backlog units at increasingly better margins. In fact, our production schedule is almost full through the end of fiscal ‘23 Q3 with some production slots left for EPA EV orders. While on some models, Type D for example, we are sold out for the entire year, currently, we are filling the remaining slots open for fiscal ‘23 Q4 for Type C and EVs at very good margins. On Slide 18, looking at fiscal year ‘23, we want to share with you our forecast by quarter, which serves as a basis for our fiscal ‘23 total year guidance. We are taking a more transparent and conservative approach this year, but it will still be a somewhat uncertain year from a supply chain perspective, yet we are confident that we have course corrected all of the other business levers that we could address. Looking at fiscal ‘23, Q1, our normal year historical results are around $5 million as this quarter has a lower number of production days and sometimes seasonally labor-related higher expenses related to calendar year-end. Taking into account the headwind of $10 million from missing pricing, we expect to end fiscal ‘23 Q1 around negative $5 million. All of our quarterly forecasts are plus/minus $2.5 million. So the range we expect is negative $7.5 million to negative $2.5 million adjusted EBITDA for this quarter. Moving to fiscal ‘23, Q2 and Q3. We have higher prices taking hold, higher revenues, small improvements from lower material costs, partially offset by increased labor costs due to cost of living adjustments. Therefore, we forecast $220 million to $240 million in revenues and $10 million in adjusted EBITDA for Q2 and $230 million to $260 million in revenues and $15 million adjusted EBITDA for Q3, each with a margin of plus/minus $2.5 million. Finally, in fiscal ‘23, Q4, with higher volume, increased EV mix, best pricing and lower material costs, we expect to generate $250 million to $280 million in revenue with adjusted EBITDA of $20 million, plus/minus $2.5 million. Putting it all together for the total year, we expect revenues in the range of $900 million to $1 billion and adjusted EBITDA of approximately $40 million with a range of $35 million to $45 million. Moving to Slide 19. We expect in summary, a significant improvement year-over-year in all aspects, with revenues up approximately 20% of $900 million to $1 billion, adjusted EBITDA of $35 million to $45 million and positive free cash flow of $0 to $10 million. However, if you look at the second half expected results from the prior page, it shows a full year run rate of $70 million of adjusted EBITDA on revenues just above $1 billion, which is back to the recovery top level of performance and set us up for taking it to the next level in fiscal year ‘24 and beyond. Moving on to Slide 20. We want to provide you with a refreshed look at our outlook beyond 2023. Once the supply chain further normalizes, we expect to sell approximately 9,500 units, including 1,500 unit EVs and generate $100 million or 8% adjusted EBITDA and $1.25 billion in revenues. This could be as early as fiscal year ‘24 if the business environment is stabilizing by then. Looking beyond that, in the medium-term, our EV growth and operational improvement can support volumes of 10,500 to 11,000 units, including EVs in the range of 2,500 to 3,500 units, generating revenues of $1.5 billion to $1.75 billion, with adjusted EBITDA of $150 million to $200 million or 10% to 11%. Our long-term target remains to drive profitable growth towards $2 billion in revenues, comprising of 12,000 units, of which 5,000 are EVs and generate EBITDA of $250 million or 12%. We are incredibly excited about Blue Bird’s future. And now I will turn it over back to Matt to further expand on this.