Mark R. Widmar
Analyst · Goldman Sachs
Okay. Thanks, Mike, and good afternoon. I'll start with operations on Slide 6. In Q4, our production was 540 megawatts, up 37% versus the prior year, but down 2% quarter-over-quarter. The year-over-year increase was driven by capacity expansions in Germany and Malaysia. Sequentially, in order to better align our supply with market demand, we idled our Malaysia facility over the year-end holiday season. This downtime reduced our capacity utilization for the quarter to 94% or 600 basis points below the third quarter. Malaysia now, though, is currently running at full capacity. At our 2012 guidance call in December, we stated that we will be running our manufacturing plants at 80% utilization in 2012. As demand in Europe is more challenged than expected, we will be reducing our utilization rates further to a range of 60% to 70% which will reduce our production in 2012 to a range of 1.5 to 1.8 gigawatts. As part of this process, we are suspending 4 production lines for up to 6 months in Frankfurt-Oder and accelerating our go-fast efficiency roadmap by idling and retooling each line sequentially in Malaysia. These actions might not be sufficient to reduce production to a level that aligns with demand, so additional actions might be necessary as we continue to adjust production capacity to match expected market demand. Because we will not be running at full capacity, we will not be disclosing our line run rate on a quarterly basis. That said, we continue to make improvements for our line throughput, helped by our advancements in module efficiency. Thus, we will -- we are increasing our goal for our line run rate from 80 megawatts per year by 2014 to over 90 megawatts by the end of 2015. Our average line conversion efficiency for our modules was 12.2% in the fourth quarter, which was up 0.6 percentage points year-over-year and up 0.4 percentage points quarter-over-quarter. This is our largest sequential increase since 2007. Our best plant improved to 12.6%, which is up from 12.4% last quarter and 11.6% last year. We continued to make significant progress in conversion efficiency. And for 2012 year-to-date, our average conversion line efficiency is 12.4%, up 200 basis points from the end of the year. And the current efficiency rate of our modules produced on our best lines in 13.1%. We expect sustained improvements in efficiencies as we continue to invest in our technology. Last month, we announced that we received confirmation from the National Renewable Energy Labs or NREL that First Solar achieved a record 14.4% efficiency for cad tel thin-film module, which eclipses the prior record of 13.4%, also held by First Solar. The record performance comes to us 6 months after First Solar announced that they had achieved a record 17.3% efficiency for cad tel thin-film cells. Both the cell and module record setters were constructed using commercial scale manufacturing equipment and materials that can be implemented across our existing line for capital spend of around $100 million for each of the next 3 years. The achievement supports our module efficiency roadmap, updated last month and underscores the tremendous ongoing potential of cad tel. Module manufacturing costs per watt for the fourth quarter was $0.73, which is down $0.01 quarter-over-quarter. This cost includes $0.01 impact from increase in the warranty accrual rate and a $0.01 headwind from a plant underutilization. Had our plants run at a full utilization, as we historically have, then our module manufacturing costs per watt would have been $0.72 or $0.03 below the third quarter on a comparable basis. Our best plant is manufacturing modules at a cost of $0.69 per watt excluding the impact of underutilization. Moving onto Slide 7. We show our updated view of available capacity and anticipated production utilization. This updated slide no longer includes Mesa. In our guidance call for 2012 in December, we noted that production in Mesa would be delayed until 2013. As we further evaluate market demand and our capacity requirements, we have now decided to put Mesa on hold until market demand justifies additional capacity. First Solar will retain ownership of the building associated with the site, and we expect to relocate various engineering and administrative work groups to the office space there. Some of the space on the main floor will also be used to store products and equipment in transition. Moving to manufacturing to our systems business on Slide 8. In 2011, we added approximately 650 megawatts AC of contracts to our pipeline and installed approximately 425 megawatts DC. Our pipeline stands at 2.7 gigawatts AC, which represents the sum of the contractual megawatts of the projects in our pipeline. As of the end of the first -- fourth quarter, we have recognized revenue for approximately 180 megawatts equivalent. The remaining pipeline will either be constructed in the future or is currently under construction, but all revenue recognition criteria have not been met. Megawatt equivalence is calculated by taking total cumulative revenue recognized divided by the total contracted revenue for each project multiplied by the megawatts for such project. Mike also discussed the solid progress we were making our for our 4 large projects: Agua, AVSR, Topaz and Desert Sunlight. In addition to these large projects, we continue to advance the balance of our systems pipeline. In the first quarter of 2012, we have begun construction on Copper Mountain 2 and received initial funding under the contract. In addition, outside of the 4 large projects previously mentioned, we had completed the financing of one of our projects subject to certain conditions, which we anticipate announcing in closing of the projects in the next couple of weeks. Moving on to the financial portion of the presentation on Slide 9. Net sales for the fourth quarter were $660 million, down from $1 billion last quarter. The decrease was primarily due to lower third-party module volumes and lower module and balance-of-system volumes in our systems business. Our EPC revenue mix decreased from 39% of total net sales in the third quarter to 30% of net sales in the fourth quarter. Our solar power systems revenue, which includes both our EPC revenue and solar modules used in the systems business, decreased slightly from 65% of sales in the third quarter to 64% of sales in the fourth quarter. Aggregate module ASPs increased 2.9% quarter-over-quarter including the impact of currency or 4.1% excluding currency. Module ASPs in the systems business increased sequentially whereas third-party module ASPs declined 4%, excluding currency. We expect the largest sequential decline in the third-party module ASPs from the fourth quarter of 2011 through the first quarter of 2012, as higher-priced legacy contracts expired at the end of 2011. On a year-to-year basis, fourth quarter module ASPs decreased 2% and third-party ASPs declined 24%. Gross margin was 20.9%, down 16.8 percentage points from the prior quarter. The decrease was due to an increase in incremental warranty charges primarily related to our previously announced manufacturing excursion. Absent these onetime charges, gross margins would have been 36.1%. Module gross margin was 19.5%, down from third quarter module gross margins of 41.4%. Excluding the impact of incremental warranty charges, module gross margin would've been 35.5%. Operating expenses were up $467 million quarter-over-quarter to $623.4 million. The primary reason for the increase were a series of charges that we considered nonrecurring, namely a $393.4 million goodwill impairment; a $31.8 million in lost power compensation related to the manufacturing excursion and $60.4 million of restructuring charges, which consisted of $53.6 million for asset impairment and associated decommissioning and $6.8 million in severance. These restructuring charges were previously announced in our 2012 guidance call last December where we said the total charges could be up to $85 million. The goodwill impairment is a noncash charge that does not affect our cash position or cash flows from operating activities. The goodwill was primarily related to the acquisitions of OptiSolar in 2009 and NextLight, representing benefits from expected synergies, economies of scale and vertical integration. We allocated most of the goodwill for these acquisitions to our components business, consistent with our historical view of the systems business’ function as being an enabler for the components business to drive module throughput. We believe that the acquisitions of OptiSolar and NextLight have provided tremendous value to First Solar far in excess of the acquisition costs including goodwill. As a result of these acquisitions, First Solar has announced the sale of and is currently constructing 4 of the largest solar power plants in the world. This impairment charge does not change the value of the acquired project pipeline nor does it change the company's view of its business prospects or future results as discussed later in this call. It is primarily triggered by the fact that the market capitalization of our stock was trading below the book value as of the end of the fiscal year 2011 and the related pressure is on the industry as a whole. In order to provide a comprehensive view of the manufacturing excursion and warranty charges in Q4, a breakdown is provided on Slide 10. For the quarter, we expensed $163.5 million. Of this amount, $125.8 million was for the manufacturing excursion. As Mike mentioned previously, a large volume of claims made under the manufacturing excursion program were processed in the fourth quarter, and we identified a significant increase in remediation costs under the terms of our voluntary program. The Q4 costs associated with the manufacturing excursion is composed of 3 items. The first item is the cost to remove, replace and provide logistical services related to the manufacturing excursion. In the fourth quarter, we expensed $23.9 million for these efforts and have expensed $99.7 million to date. The second item is expected payments to customers under certain conditions or power loss prior to the remediation of the customer system. In the fourth quarter, we expensed $31.8 million for this compensation and have expensed $45.9 million to date. The third item, $70.1 million, is due to an increase in expected number of replacement modules above our standard warranty rate required for our remediation efforts. Finally, we recognize the $37.8 million charge to increase our warranty accrual. We believe our PV modules are potentially subject to increased failure rates in hot climates. As a geographic mix of sales has shifted to hot climates, we have increased our warranty accrual. Our experience has shown that our warranty rates for hot climates are slightly higher than the return rates for temperate climates. With this change, our standard warranty accrual rate has been increased by 1 percentage point to account for the potential returns going forward. We will continue to review our warranty accrual rate in the future, and we'll adjust the rate as appropriate to reflect our actual experience. Due to the charge for goodwill impairments, additional warranty accruals and restructuring, we've recorded an operating loss of $485.3 million for the quarter compared to an operating income of $222.7 million in the third quarter. The fourth quarter net loss was $413.1 million or $4.78 per share. The effective tax rate was 14.2%. Before the nonrecurring charges mentioned above, that is, goodwill impairment, additional warranty accrual and restructuring, earnings per share for the quarter would be $1.26 on a fully diluted basis and the effective tax rate would be 19%. Overall, our fiscal year 2011 net sales grew 8% from 2010 to approximately $2.8 billion. On a GAAP basis, operating margin was negative 1.3% and earnings per share was a loss of $0.46. Excluding the full year impact of the items listed above, the full year diluted EPS would be $6.01. Slide 11 presents a walk from our GAAP EPS to our non-GAAP EPS for the fourth quarter 2011 and for the fiscal quarter -- or the fiscal year 2011, calling out the 3 nonrecurring charges related to warranty, goodwill impairment and restructuring. The complete reconciliation of GAAP to non-GAAP numbers can be found in the slides at the back of the presentation. Turning to Slide 12. I'll review the balance sheet and cash flow summary. Cash and marketable securities were $788 million, down slightly from $795 million as of the end of the last quarter. Accounts receivable trade balance declined quarter-over-quarter due to improved collections and lower shipments. Our unbilled accounts receivables increased $208 million due to a $224 million increase in unbilled receivables at Agua Caliente. Inventories increased mostly due to higher inventories in our systems business, both for modules and balance-of-system's equipment, partially to help secure the economic benefit of the 1603 Program for our projects. Project assets increased as we proactively developed projects that we have not yet sold. Deferred project costs also increased as we constructed projects that we have sold, but for which we cannot yet recognize revenue. As a reminder, when we sell a project, the project assets turn into either revenue or deferred project costs, depending on whether the applicable revenue recognition criteria have been met. Our debt level increased by $55 million from the end of last quarter, primarily to fund working capital increases on our systems business as certain projects anticipated to close were pushed out of the year. Operating cash flows for the quarter were $11 million, and free cash flow was negative $76 million. We spent $118 million for capital expenditures, down $106 million from last quarter. Depreciation was $67.9 million compared to $60.8 million last quarter. This brings me to our updated guidance for 2012. We are reaffirming our guidance for net income and earnings per share, excluding any impairment and restructuring charges that we may be taking this year. While earnings guidance is the same, the assumptions behind the guidance have changed, as shown in Slide 13. As we mentioned earlier, the euro market will be more challenged than we initially expected. So our third-party sales are expected to be in the range of 300 to 500 megawatts, down from prior guidance of 720 megawatts. To accommodate lower sales, we will further reduce our manufacturing utilization rate to a range of 60% to 70%. This will increase our module manufacturing cost per watt from $0.67 under fully utilized to $0.74 underutilization rates of 60% to 70%. Note that our profits, excluding underutilization, is the same as we have guided in December despite incurring a $0.01 headwind due to higher warranty accruals going forward. The reason is that we continue to accelerate our efficiency improvements. We now expect to average a module efficiency of 12.7% in 2012, up from the prior guidance of 12.6%. Turning to our guidance on Slide 14. We're reducing our 2012 revenue guidance from a range of $3.7 billion to $4 billion to a range of $3.5 billion to $3.8 billion to account for the lower third-party module volume. Offsetting the impact of the lower third-party module sales and the higher module manufacturing costs due to lower production volumes is favorable balance-of-system costs productivity associated with our systems business, where we plan to install 1.2 gigawatts of modules. Our operating cash flow guidance declined due to the 2012 cash impact associated with the incremental manufacturing excursion charges accrued as of the end of 2011. Our operating cash flow guidance for 2012 includes approximately $75 million of net cash receipts from Desert Sunlight. To summarize on Slide 15, overall, our operating performance for the quarter and year-end were solid, given the challenging market condition. We expect challenges in the subsidized markets to intensify in 2012, due to uncertain and in some cases, collapsing FiT regimes. Cash flow generation should accelerate in 2012 as working capital turns into cash flows. We are accelerating module efficiency and cost roadmaps to increase our competitive advantage. We are developing a 3-year plan to aggressively enter the sustainable markets, the details of which we will unveil in the first quarter earnings conference call. With this, we conclude our prepared remarks. And we welcome the questions -- the call for questions. Operator?