Louis Gries
Management
Okay. Good morning, everybody. We'll go ahead and get started. Appreciate you joining the results announcement call for fiscal year '17. We're going to do it pretty much like we normally do. I'll give an overview of the year, and then Matt will give you a financial overview. One thing I'm going to do differently, since this isn't a typical Hardie year, results wise, I'm going to give you a bit of summary. As I'm finishing up my overview of the businesses, give you a summary of '17 and also a little indication -- not guidance on '18 but a little indication of how we're thinking about going into '18, and then I'll hand it over to Matt after that. You'll probably get there through Q&A, anyway, but I thought I'd give you the kind of framework that we're thinking about the year. Looks like I need something to change -- the clicker? Got it. Sorry. Okay. So a lot of red arrows in that. Quarter came in weaker than full year, and almost everything's going to come back to manufacturing. So I'm going to get into it in some detail. We even put in a couple of extra slides so we can kind of show you what that looks like. Full year, pretty flat on the profit side, better on the earnings per share, better yet on the cash flow. But again, not a typical Hardie year when it comes to delivering financials. When we go to North America, which where the main story is, you can see volume was good, price was flat, basically down a hair. And the EBIT was the lost opportunity, both in the quarter and the full year. And this summary, on the slide to the right side of the slide is a pretty good summary. It's all going to come back to manufacturing. And like I said, we'll going through that kind of step by step in a couple of slides. But on our network of plants, our efficiencies were down some so that affected us. We had less throughput than we thought we were going to have for servicing orders. And we also had higher costs due to these inefficiencies. Then we had a big challenge on start-ups, which two of them didn't go as well as we'd wanted. One went really well. The one in Texas went really well and the one in -- the ones in California and Florida didn't go as well as we would have wanted. Being short, on throughput drove higher freight cost. And the last point, which is separate to manufacturing, we did put some capability into the business. And that was a fairly significant step so it wasn't lost in the bottom line. But manufacturing is still the story on the bottom line. I must be pointing this the wrong direction. Okay, price. You can see, we've been flat on price for a couple of years. That'll change this year. We did take a price increase April 1, so we'll be up about 3% next year. Flat for two years on price when our inputs were going up, so that did put kind of an incremental drag on EBIT during that period. But again, that's not the main story. It's how we performed on the operations side. The top line growth slide, which we always show you, is fairly typical. Housing starts have been increasing year-to-year at a fairly moderate pace. And we expect it to look that way next year as well. This year says volume and revenue were about the same growth rate. There's no separation between the two lines on the top. They're the same slope, but obviously, we got a slope advantage over the housing starts. We continue to do well in repair and remodel, which is actually our bigger segment. This is a new slide. We've never provided it and probably won't in the future, just kind of to give you a head's up. We're still part of the story. On the manufacturing, you can see, on the left is your kind of existing capacity that was running coming into the year. And we gave you a little bit of historical because we've been talking about we were running with some inefficiencies we hadn't planned on. And that's what you see in the last four quarters, We were coming off a very good trend line, which was almost eight quarters long, where we had really -- in fiscal year end of '15, start of '16, we took on a pretty major manufacturing initiative that did drive up our throughput rates in the plants. So we started banking on those rates. And you can see this quarter, we obviously didn't go back to where we were previously, but we did drop down a little part of what we consider our normal range for manufacturing. The right-hand side of the chart just tells a little bit of the story on capacity. So we have a nameplate capacity of 3.4 billion that are operating, that's for operating plants, and that includes your start-ups. And then you have 0.3 billion, so 300 million feet, that isn't operating. That's the Summerville plant and -- one of our lines in Plant City. So currently, we're early stages of starting both those lines up, but in fiscal year '17, we didn't have any product off either of those. Now when you drop down from 3.4 billion down to 2.6 billion, which is really our current capacity, the 800 million feet is made up of basically 3 things which we list on the bottom. The first is something that's in the business, and that's -- our nameplate capacity is based on 5/16-inch, full-width on a machine, medium-density fiber cement. And then you have a product mix that varies from that. And about half of the 0.8 billion or 800 million is 400 million in product mix. Now we do have some technology projects, working on speeding up some of the products that fall into that category, but you should think of that 400 million, as kind of just built into the system. The other 400 million is either gross hours not run or the line efficiencies that we've talked about. So it's either gross hours or it's rate -- number of gross hours or rate per gross hour. The rate per gross hour, we've already talked about on the slide to the left -- or the chart to the left. The gross hour utilization is not all kind of lost opportunity. You have bottlenecks that drive some of that as well. So if you've increased the throughput in a plant and you don't have enough silica supply, which we grind our own silica, then you can't run the gross hours whenever you've topped out on silica. Certain products use a lot more silica than other products, so a lot of times, that comes to how well you're running and what products you're running. Sometimes, as you expand the plant, you start putting the autoclaves in place and they get delayed. So there is a good -- and the only thing I'd tell you on our nameplate capacity, we basically went to a theoretical design back in the late '90s. And at that time, we had mostly small-scale plants. And we, in our calculation, we had eight hours a week to clean up a plant, to do your maintenance, clean it up and restart it. As we get into larger plants, the time to clean them up actually goes up. So now, they're 12, 14, 16 hours. Now we're, again, just like the example on the product mix, we had some projects in place that are starting to compress that time. The main reason I went into that long explanation, I want to you to understand this is not a sight from necessarily the gross hour. Although, there are some slight opportunities, it's more where we're at in the development of our network in the company. So this just steps up our capacity since the downturn. So you'll remember, we idled a lot of capacity during the downturn, and then we also reduced gross hours on capacity that was running. So when we started to get volumes back, coming out of the downturn, the first thing we did is just increased our hours on the lines that we were running. And then we started to bring up capacity that had been idled. So you can see, in fiscal year '13, we brought up a line that was idled in Loxahatchee. And then in '14, at a very low level, we brought up the line that was idled in Fontana. Now we kind of re-engineered that facility because we pulled out one of the lines, put in a much larger, higher-throughput line, and then shared the mix plant autoclave, raw material supply for that plant. So it's kind of the re-engineered facility, but the first step to start it up was just to start up the line that didn't have as many changes on it. The old line, not the new line. And then where we got here, in fiscal year '17, and kind of becomes our story for '17, we got in a very tight supply situation. We had miscalculated the capacity that was going to be needed and the amount of time to bring it up, and we were forced to bring up 700 million feet of capacity in one year. And I think our organization has shown that even though the effort was good, we weren't ready to do that well. And that kind of drove, that has driven our bottom line problems during the year. There's a few other parts of the story, which I'll cover, but, and you can see it starts showing up late in the year. You can see, kind of from our working capital year-to-year, we came into the year with pretty good inventory levels and pulled those down as we weren't able to keep up with demand early in the year. And then as it became hand-to-mouth situation on board, we started to really see the inefficiencies in freight and also the inefficiencies in spend as we throughput optimized the network. There's kind of four things that are driving delivery unit costs up. One of them, I covered, it's the inefficiencies of the current network weren't as high, were higher than prior year, and then the start-up costs for the new lines. But we also have an infrastructure cost that we took on as part of a commitment we made in July to go to best-in-class on safety, which we were at, at what we call two and 20 rate, which is a good rate for our type of industry, I think it's in the top quartile or right around there, some 75th percentile. And we just -- we had an accident in a plant. When we investigated the accident, we didn't like what we saw, but also, part of that investigation, it kind of opened our eyes to the fact that at a 2 and 20, at the growth rate in our business, that's just a lot of accidents in our facilities even though it's small on a relative basis -- per 200,000 work hours, it's still a lot for our company. And we felt we owed it to our employees to really aim for a much higher level of safety, which we call zero harm. We had a corporate task force -- corporate, I say. It was led by our GC, but we had representation from each of our sites. And they did a 6-month basically current-state assessment gap analysis. And one of the big areas they identified early on is our infrastructure -- our spending on infrastructure wasn't keeping up, so we're letting -- things like ventilation, lighting, just cleanliness at a plant, how things were aging over time, we now have plants that are 25 years old, just wasn't consistent with a zero-harm, best-in-class safety. So we put in a program to start catching up on that infrastructure spend. And when I say catch up, we have to spend at a higher level. That's how we got behind, but it's not a catch up like you'll see in maintenance. Maintenance is more of a 9- to 12-month catch-up. This is more of a 3- to 4-year catch-up. So we'll continue to spend at about that $10 million to $15 million a year on upgrading existing facilities. And again, the base of infrastructure, I'm not talking about new machines or anything, lighting, concrete work, buildings, guarding, just everything that makes a work environment for the employees. So I covered start-ups, I covered inefficiencies, I covered infrastructure. I kind of alluded to high freight because you now have throughput optimizing. And the fifth thing is the maintenance catch-up. So when we -- you saw the chart where we really shifted the rate of throughput per gross hour in our plants a couple of years ago, so it was a surprise to us when we started to lose the efficiencies in a plant. And one of the root causes of that has been that, unfortunately, we had taken a short-term view on maintenance spending plan over in the last 18 months or so, and that was starting to run into higher unscheduled delay and some long, large delays. And some of this was big things like wall mills, feed pumps, stackers, conveyors. And some of it was more just the 47 pumps that are on a sheet machine. So pumps and motors, stuff like that. That spending kind of peaked in Q4, which is one of the reasons you were probably a bit surprised by our result in Q4. It had kind of risen to a high level in Q3, peaked in Q4, and it's now starting to taper off. Now we'll end up -- obviously, because we are underspending, we'll end up at a higher level than we had been the last couple of years but a much lower level than we have been in fiscal year '17. Okay. So that's the U.S. and I do have a summary, and the summary is basically the U.S. because the U.S. is the driver of the result this year. Asia-Pac, our Asia-Pac had a very good year. Pretty much everything points up. The only bump in the road this year in Asia-Pac was the Philippines. Australia, very strong result. Volume, price, cost was good. You could see, we're starting to get the efficiencies out of Carole Park. We had the big start-up costs their last year, so that's kind of an easier comp. But it's also good that we're starting to get the inefficiencies that we saw when we went to put the investment. New Zealand, not as good of a story as Australia, but again, another good contribution year out of New Zealand. And then the Philippines, we ran into a competitive situation, offshore competitive situation that affected both our volumes and price to some degree. As far as how the business is operating, it's operating fine. Our market position is just being attacked. And we just have to work through that in a better way. It's just a new kind of playing field for the guys in the business and they'll sort it out, but it will take a time to sort out. It's not a big business, obviously, so it doesn't drag material numbers for the corporation. But we report -- we talk about it separately in the Asia-Pac business. So that was the negative. Everything else was positive. ANZ was very positive. Okay. I'll give you my summary. So, fiscal year '17, good growth. And the way to think about the good growth is we did get an increase in interiors, but the exteriors number was much larger, obviously. Vinyl continues to decline against its market index which is kind of the plan. We see vinyl as a product line or a product that's in decline, hard sidings, kind of substituting for it even though it sells at a much higher cost. Both Hardie and L-P were above their market index. Now we have slightly different market indexes, but the reality is we are both above and vinyl was below. On the volume. In Q4, it looks very similar to the first three quarters. But I need to tell you, some of that is price increase pull-forward. So about 20 million feed is our estimate, it's price increase pull forward. There is basically a current dampening on demand that's going on in our business right now, and I think it's not so much a price increase pull forward, that's just a quarter-to-quarter switch; it really comes down to that we had to put the business on allocation last year. We extended lead times in some segments, and we're currently still working out of a service position that's below target for our industry. So normally, our industry service positions run in the 95 range, mid-90s. We kind of aim toward 97, and right now, our business is running more like 80s because we don't have enough buffer between capacity or supply and demand at this point. So I'll talk to that a little bit more. On the supply restrictions last year, like I said, it was just we cut it too tight and we brought too much capacity up in what amounts to just over a one year window. And that goes back to what I talked about Fontana, PC4 and Cleburne 3 were the main, that was the capacity coming up. Cleburne 3 went very well. That was the last one to come up. And PC4 and Fontana were both very difficult. And then we also had the isolated inefficiencies in the rest of the network. So I want to point out there's -- this isn't an across the network inefficiency. We had a couple of plants that we usually count on pretty heavily and have stayed at that kind of better part of the range up there, and that would be Cleburne and Tacoma. And we have a couple of plants that are really doing quite well against historical throughputs. Probably the most noteworthy would be Waxahachie. But at Peru, Pulaski, Plant City, Reno, we did have the inefficiency issues that affected our ability to supply. Right now, trend lines are positive on both start-ups and on the broader network. So we've got some momentum back. We've worked through some of our issues. Like I said, we're maybe a little bit more than halfway through our maintenance catch-up, so that's helped with some machine performance. And we have started to build back some buffer between supply and demand. A lot of that buffer was used for the price increase so it got pulled down, and now, it's being rebuilt again. So the -- again, the manufacturing EBIT issues, start-ups, inefficiency, maintenance catch up, infrastructure increase, high freight and all that basically just results in higher unit delivered costs. So we had plenty of volume. We had a price we were expecting, but we had a much higher cost than we were expecting. So obviously, this time of year, we don't give you guidance for fiscal year '18, so I'm just going to talk about how we're thinking about fiscal year '18. Just as a bit of an update, the order file is soft right now. So how much of that is the price increase pull-forward, and how much of that is the dampening due to the allocation situation we're out of now. The lead times have been pulled back to normal, but our service position is still tighter than we'd like to see. The higher delivery unit cost will decrease as we move through the year, so it's not over now. So I think most of you know we have about a 45 day lag with cost -- of producing versus cost of goods sold. That's what -- obviously, what goes into the inventory. We are just tapering off on the maintenance spend. I think that will kind of get back to where we consider our new normal levels maybe July or August. So we're still spending more than we will as a rule in the future, we do have the start-up -- I mean, the throughput improvements, they're going to help us, start-up improvements helping us. Now this year, we're only going to start up 300 main feet of capacity. And that's not that easy, but it's not 700 and they're not brand-new lines. So they're existing lines that have been kind of re-engineered to a small degree for start-up. We are, in PC, changing its product mix, so that's a little bit -- Plant City that is, that's a little bit more of a challenge than Summerville, which is coming up with some improvements but roughly the same production lines as we shut down. I already talked about infrastructure. Spends will continue, so that's $10 million to $15 million. Freight will start coming off, but we've got to get the service position up before the freight starts coming off. So that probably starts coming off more toward the second half of the year. Raw material and energy is going to be up this year. Pulp looks like it's going to be both more expensive than last year. Cement, obviously, we signed annual contracts, so we know that will be up. Gas is up a bit coming off of an historical low. We'll have some more cost increases, like I commented about '17, but not at the same rate. So basically, my summary is we're going to start the year low in our range, and we're going to build to high in our range late in the year. And I think the growth's going to go the same way. I think we'll have a small comp -- a small PEG comp, Q1, which is a little short for a PEG comp, but just how we think about it, above the index. We'll be starting out small in Q1, and I think as we get out of our service position and get back on a front foot in the field with our customers, get these allocation and lead time issues kind of further behind us, I think we'll be able to deliver bigger comps late in the year. So that's just a general kind of update. So when you ask your questions, we can drill down a bit. But at this point, I'm going to hand it over to Matt for the financial review.