Mark Widmar
Analyst · ROTH. Your line is open
All right. Thank you, Alex. As our company’s founding Over 20 years ago, the PV industry has been through periods of rapid growth, declining costs and technology evolution. We’re one of the few solar companies that both entered and exited this last decade. We have continued to adapt our business model to remain competitive and differentiated in a constantly evolving market. For example, our original assets into O&M and EPC and project development was to address an unmet need of the market and capture a profit pool. Our acceleration of Series 6 production was a competitive response to address the current market condition. Despite these transformation among others, our core identity as a module manufacturing company with a differentiated CadTel technology has remained constant. As we look into the future with a more focused business model, our pace of innovation will be critical to our competitive strengths, enabling us to leverage our points of differentiation and capture compelling value for our technology. CuRe, cell crackling warranty, and responsible solar strategy are recent examples of innovations enhancing our competitive position in the market. The market momentum for PV continues to build. Our Series 6 energy, quality and environmental advantages are all key demonstrators, which we believe we’ll enable us to meaningfully participate in this wave of demand for clean and affordable energy. Based on the growth of selected people markets and our competitive advantages, we believe we can grow our manufacturing capacity while still selling our products into regions where our technology has points of differentiation. Within this context, Slide 9 provides an updated view of our global potential bookings opportunity, which now totals 19.7 gigawatts across early to late-stage opportunities through 2023. In terms of segment mix, this pipeline of opportunities is exclusively third-party module sales. In terms of geographical breakdown, North America remains the region with the large number of opportunities at 14.9 gigawatts. Europe represents 2.3 gigawatts. India represents 1.8 gigawatts with the remainder in other geographies. A subset of this opportunity set is at mid- to late-stage booking opportunities of 12.6 gigawatts, which reflects those opportunities we feel could book within the next 12 months, and includes the aforementioned 1.4 gigawatts of contracted volume subject to satisfaction of conditions precedent. This subset includes approximately 10.2 gigawatts in North America, 1.2 gigawatts in India, 0.9 gigawatts in Europe of which 0.7 gigawatts is based in France and the remainder in other geographies. This opportunity set coupled with our contracted backlog gives us confidence as we continue scaling our manufacturing capacity. Turning to Slide 10, as we’ve continued to drive additional throughput, increased average watts per module and improved manufacturing yield, our Series 6 production exited 2020 with nameplate capacity manufacturing of approximately 6.3 gigawatts split between 4.1 gigawatts at our international factories in Vietnam and Malaysia and 2.2 gigawatts in Ohio. With the commence production at our second Series 6 factory in Malaysia, our global manufacturing footprint increases to six factories. At the end of 2021, we anticipate increasing nameplate capacity to 8.7 gigawatts, which includes 2.6 gigawatts of capacity in Ohio and 6.1 gigawatts across four factories in Malaysia and Vietnam. This 2.4 gigawatts in incremental year-over-year capacity is reflective of our new Malaysia factory and expected improvements in average watts per module and throughput across the fleet. By the end of 2022, we anticipate increasing throughput by 12% compared to our rebated throughput entitlement and expect continued improvements in our average watts per module and manufacturing yield. Accordingly, by the end of the year, we anticipate increasing our fleet-wide nameplate manufacturing capacity to 9.4 gigawatts, which includes 2.7 gigawatts of capacity in Ohio and 6.7 gigawatts across our international factories. This 0.7 gigawatts anticipated incremental capacity is expected to come from optimization of our existing footprint. As previously highlighted, we are evaluating the potential for future capacity expansion and they think to further diversify our manufacturing presence. In addition to the factors we’ve previously highlighted, we’re also evaluating domestic and international policies to ensure any such expansion as well-positioned. While we have made no such decisions at this time, any Greenfield capacity additions are unlike contribute to our 2022 production plan. From our production perspective, in 2021, we expect to produce approximately 7.4 to 7.6 gigawatts, which is within the 7.3 to 7.7 gigawatts range, we provide at this time the last February guidance call. Note, our second Malaysia factory will continue as ramp period through the end of the first quarter and we are planning for over three weeks of downtime across the fleet to implement technology and throughput upgrades. In 2022, with the addition of the fully ramped factory in Malaysia and ongoing improvements across the fleet, we expect to produce 8.6 to 9.0 gigawatts. Turning to Slide 11, I will now provide an update on our technology roadmap. Over the course of 2020, we’ve made steady progress in our technology roadmap and in the year with a top bin of 445. Early in 2021, we have demonstrated continued progress increasing our fleet wide average per module to 444. For February month-to-date and for our new Malaysia factory introduced our Series 6 plus module, the next phase of our technology roadmap with a current top bin of 450 watts. Leveraging our existing Series 6 toolset, we increased our module form factor by approximately 2% and increased our module efficiency, which has increased our top bin production by approximately 10 watts. Note, after our second Malaysia factory ramp is completed, we anticipate our top bin will be 455 watts. Importantly, this increase in form factoring is sized to reduce balance of system cost per watt by adding module wattage, without material changes to the installation process or support structure. We anticipate implementing Series 6 plus across the fleet over the course of 2021. From our manufacturing cost perspective, we expect this additional wattage reduce our costs and sales straight freight per watt, which I will later discuss. For the fourth quarter of 2021, we anticipate commencing initial production of our copper replace Series 6 or CuRe on our lead line production. As previously disclosed, this program is expected to not only increase module wattage, but also meaningfully improve lifetime energy performance. Accordingly, by the end of 2021, we anticipate our top production bin will reach 460 to 465 with an expected 30-year warranty degraded rate, approximately 50% below our existing baseline. Given PV power plants have an expected useful life of up to 40 years, our reduction in a module is long-term degradation is expected to be a material benefit to project economics, as it increases energy density of the module and life cycle energy generation. As demonstrated on Slide 12, we believe that benefits of improved module efficiency and temperature coefficient will result in a 7% higher energy density in the first year for our 465 watt CuRe module compared to our 440 watts Series 6 module. Due to the expected reduction in our CuRe modules long-term degradation rate, we expect is improvement can increase to 20% in year 40, which represents a 13% improvement over the life of the asset. As we stated previously, we believe CuRe’s significantly increases Series 6s competitiveness against bifacial modules. As a point of reference, bifacial modules generate in an estimate of 4% to 8% more energy than comparable monofacial modules. More importantly, CuRe’s energy uplift does not increase the module or balance assistant cost as typically seen with bifacial modules. By the end of the first quarter of 2022, we anticipate the entire fleet will be converted to CuRe. This is anticipated to provide additional benefits to our average watts per module and cost per watt. Through the implementation of our copper replacement program combined with our ongoing R&D program, we’re aiming to achieve a top production bin of 475 to 480 watts by the end of 2022. Note, on our second quarter earnings call, we stated that we expected a 480 watt module bin 2023. With a CdTe cell efficiency entitlement in an excess of 25%, we see a path to significantly increase our module outage and efficiency in the midterm. With this path to increase efficiency coupled with our degradation, spectral response and temperature coefficient energy advantages and vertically integrated manufacturing processes, we believe the outlook for our technology remains well positioned in a global PV market. Finally, we continue to focus on advanced research and development under evaluating the potential to move beyond a single junction device and leverage the high-band gap advantages of CdTe in a multi-junction device. A multi-junction device has the potential to be disruptive high efficiency, low cost module within advantage energy generation profile. Well, the evaluation for this technology is in early development, we are aiming to utilize many of the product enhancements in our existing CdTe roadmap. Turning to Slide 13, I’ll provide some context around our module cost per watt, as initially presented on our guidance call in February 2020, we forecasted a Series 6 cost per watt reduction of 10% between where we expected to end 2020 and the end of 2019, despite unforeseen challenges related to the pandemic pricing pressures and the global shipping market and rising commodity costs, including aluminum, which we mitigated in part through a hedge structure and increased demand for PV glass, we executed on our cost per watt roadmap for the year and achieved this target. Looking into 2021, I’d like to start by addressing how we intend to manage key bill of material and sales freight costs. Firstly, given our module utilizes CdTe chemistry, our cost per watt is unaffected by fluctuations in polysilicon pricing. Secondly, from the glass perspective, growing solar demand and the emergence of bifacial modules have continued to put pressure on the supply and cost of PV glass. However, our glass procurement strategy primarily relies on forward contracts and localization of glass supply. In 2021, we intend to further localize our glass needs domestically in the United States and Malaysia through long-term supply agreements. This strategy enables us to mitigate the cost of variable spot pricing for glass and inbound freight. Thirdly, from a sales freight perspective, utilizing contracted routes and minimizing changes helped alleviate some of the impact of higher spot rates in 2020 in the first quarter of 2021. Despite higher shipping rates expected in 2021, we intend to utilize our distribution center strategy to mitigate some of these events. Note, we expect sales freight and warranty to produce module segment gross margin by 7 to 8 percentage points in 2021, compared to 7 percentage points in 2020. Finally, as part of our Series 6 plus implementation, we anticipate a reduction in the module profile by reducing the thickness of our frame and junction box. In addition to reducing the bill of material costs, we anticipate this development will enable us to increase modules per shipping container by approximately 10%. As it relates to our Ohio manufacturing facilities, despite exiting 2020 with a higher cost per watt in comparison to our international factories, we have displayed significant improvements in 2021 through the following initiatives. Firstly, in the fourth quarter, the manufacturing yield was 96%, which was below the fleet average. We anticipate this will improve to 97% by the end of 2021, which provides a benefit to our fixed and variable costs per module. Secondly, we anticipate increase in our nameplate manufacturing capacity to 2.6 gigawatts by the end of the year, an increase of 18% compared to the end of 2020. Finally, our cover glass facility in Illinois started in the fourth quarter of 2020 and a float glass facility in Ohio started in the first quarter of 2021 and we’ll supply our Ohio factory. We anticipate this will provide a benefit to the variable portion of our cost per watt. With the implementation of these key initiatives among others, we anticipate our Ohio cost per watt headwind relative to our international factories will exit 2021 $0.02 per watt higher, including sales freight. On a fleet wide basis, relative to where we exited 2020, we anticipate reducing our cost per watt produce by 11% by the end of 2021, due to the ramp and underutilization costs related to the affirmation factory ramp upgrades and challenges related to sales freight, we anticipate reducing our cost per watt sold by 8% by the end of the year. As we look beyond the midterm, I would like to revisit the five key levers that we believe will enable us to continue to reduce in our cost per watt. Starting with efficiency, we anticipate increasing our top production bin from 445 in December 2020, a top production bin of 475 to 480 watts by the end of 2022. With a midterm goal of 500 watts per module, we see the potential for continued improvement in our module performance. Improvements in module watts generally provide a benefit to each component of the cost per watt, including our variable and fixed bill of materials and sales freight in warranty costs. Secondly, by the end of 2022, we anticipate increasing throughput by 12% compared to our rerated capacity utilization baseline to the implementation of the additional tools and debottlenecking efforts. This drives additional throughput on our existing manufacturing footprint resulting in the fixed cost solution benefit. Thirdly, while we’ve made steady improvements to our manufacturing yield over the course of 2020 achieving 97.6% in December, we anticipate a fleet wide yield of 97.5% in 2021. While our international factories have achieved yield, in excess of 98%, the plant upgrades for Series 6 plus and CuRe are expected to impact yield performance during the year. However, in the midterm, we see a path to increase our fleet-wide manufacturing yield to 98.5%. Fourthly, we see midterm opportunities to reduce our bill of material costs by 20% to 25%, primarily across our glass and frame. Finally, we believe the combination of sending our module profile and transportation optimization can lead to a 15% reduction in freight costs. Combining the benefits of our CuRe and our other R&D work with aforementioned cost levers, we believe we are strongly positioned to continue to drive Series 6 cost per watt efficiency and energy improvements over the near and midterm. I’ll now turn the call back over to Alex, who will discuss our financial outlook and provide 2021 guidance.