James Meyer
Analyst · Buckingham Research
Thanks, Ted, and thanks, Matt. Let's move on to the more interesting news today and talk about how we are transforming this company. I spent the last several months observing the way in which we do business each and every day, getting to know our people and processes. And as someone who's led the operations and manufacturing functions of several other capital-intensive companies, I can safely say we have a significant opportunity to not only improve but to become very, very good. I've also spent a great deal of time talking with and getting to know many of our customers and actively listening to what they want from us to be successful in their own businesses. The good news is that a few common themes permeated all of those conversations. The most critical of which are their desires to see real diversity in their supply chain and to see FreightCar succeed in building out a larger role in that chain. Their belief in us stems from our long history within the railcar manufacturing industry, which has always been based on superior car designs and on superior customer focus. Our product teams are talented and experienced, have engineered the most durable and lightweight coal cars in the history of the industry, and they have spent the better part of the decade transferring that knowledge across all of the other railcar types that we offer today, and less weight with more payload means better economics for our customers. Our products are complemented by a strong reputation as a company that puts customers first, and is willing to work with our customers to give them exactly what they need. These 2 cornerstones of our company will not change. To round out this discussion of our strengths, I want to call attention to, in the most positive manner, that we have one of the newest manufacturing platforms in our industry at the state-of-the-art Shoals facility. This is a truly unique asset that we are going to leverage much, much better, with this manufacturing platform as a U.S.-based workforce that we are investing more deeply in and better developing. Lastly, we have a very strong balance sheet and financial position that will enable us to achieve everything we set our minds on. As Matt said, this financial strength is one of our strongest and most critical assets during this turnaround period, and we will continue to both make all of the progress necessary and prudently manage cash flows. Let's now turn our attention to where we need to improve. In order to turn great facilities into great manufacturing operations, you must have the right and simplified structure, strong processes, led with a lean culture and a deepened strength. Unfortunately, FreightCar's operations in Shoals have not been fully reflective of this. In fact, we've had a high-cost structure, complex organization and a lack of basic manufacturing fundamentals. More specifically, our challenges include cohabitation on our Shoals facility. As many of you know, we have been a subtenant to Navistar international at the Shoals facility and we have not handled the complete railcar build as they have historically executed the initial fabrication, truck assembly and then paint and blast. Secondly, our manufacturing processes remain underdeveloped and inefficient and our lean learning culture hasn't been developed correctly. Thirdly, we haven't hired enough of the right people in the right positions and our training investment in our workforce hasn't been enough of a priority. And lastly, our sourcing and procurement functions need more attention. The bottom line is we have to transform the foundation of this company in order for us to win. We are sharing with you a program already commenced, that we are calling Back to Basics. There are 3 main components of this strategy, which include: one, simplifying our structure; two, developing, training and retaining the right talent across our organization; and three, implementing disciplined manufacturing processes and lean thinking. Our plan is dynamic, measured and is being executed with a sense of urgency. I'll start with the simplification of our structure, where we have new developments to discuss today. First, to help streamline our operations, we announced yesterday that we have taken control of the Shoals facility, and we'll acquire all of the operating assets of Navistar International there. This transaction will give us 100% control of railcar operations, and we will move from being a subtenant of Navistar at Shoals to the primary tenant. We will assume the balance of the lease and in return, Navistar will pay us a make whole provision of $24.1 million. Additionally, we will pay them $17.3 million for fabrication and paint and blast equipment as well as approximately $4 million for select inventory, for a total consideration of approximately $21 million. And lastly, we will retain nearly 200 of Navistar's former employees at the plant, who will now be compensated and incentivized under our umbrella. This transaction is expected to close tomorrow, subject to the conditions set forth in the asset purchase agreement. Optimizing our supply chain has been one of my primary objectives since joining the company. And with this transaction, we will be in greater control of our destiny as we can now focus on consistent and efficient production from start to finish. This is an extremely important start but it is only a start as we look to continue to streamline. Additionally, as we have previously communicated, we idled the Danville, Illinois facility in 2017 and this is now permanent. We have reallocated some of the talent from that location to other parts of the organization including Shoals. The next part of our Back to Basics strategy is focused on developing and training our people and attracting the right talent to our organization. Over the last several months, we have augmented our leadership talent through the addition of several new leaders all located in Shoals. These include a new Vice President of Operations, a new Vice President of Supply Chain, a Director of Lean Manufacturing, a Vice President of Human Resources, a Director of Plant Environmental Health and Safety. Two of these 5 recruits bring historical operational experience from Danaher, a few more that I've had the pleasure to work with in past roles, and I'm thrilled to have all of them on our team. We have a very promising workforce at our Shoals facility and by giving them the proper leadership and proper tools, we will turn a capable workforce into a high-quality and high-performing workforce. Additionally, we need to invest in stronger training for our teams and we have a number of new initiatives designed around continual learning and more advanced training. And let's not forget a more rigorous commitment to safety, as it is vital that we protect our associates and properly train all of our people to remain committed to running a safe and reliable shop. Safety, quality and productivity go hand in hand. And safely -- safety is likely the best single measurement of a plant's discipline and its potential to perform. We are now performing very well in this category. In summary, we must have the right talent and we must have everyone trained to the right levels, and we will continue to recruit and invest in our team. The third component of our Back to Basics strategy focuses on the creation of tools and processes that can help us lay the groundwork to create repeatable and consistent workflows. Without these, we will continue to have productivity performance issues and missed opportunities. I'll highlight just a few of these at a high level. Visual management. We have implemented visual management for the first time to our senior production leadership is now using it to run the day-to-day operations within the plant. We are using it to track every piece of whip in the factory and every current and potential issue with the progression of the whip through the manufacturing process. New model launch process. We lose too much time and have too much expense associated with model changeovers. Frequent model changeovers are the nature of the business, and we have an opportunity to get just as good at this through rigorous and well-defined methods as other industries such as automotive. We are working on this now. Materials management. Every aspect of our materials management will benefit from process improvement and we are in the midst of implementing major process changes right now in Shoals. In the far flung, I will touch on quality systems. Just like on the new model launch process, we have much to borrow with pride from automotive and to build on to our existing systems. To conclude, these processes and many more are designed to effect significant cultural and organizational change. And while these types of processes take time to root, we will begin to see and feel the progress this year, including taking out meaningful cost. We expect to enter 2019 with direct cost of goods sold savings of at least $3,000 to $4,000 per railcar on a run-rate basis, excluding the impact of commodity movements. I want to emphasize, this does not require reinventing the wheel, rather these are some of the more basic foundational elements of a highly productive and commercially successful manufacturing entity. A lot of companies have great assets and many others have a great workforce. One starting point in our favor is that we have great assets, we have capable employees and a business legacy that enables us to recruit the additional talent we need. And this is just the start. As our company adopts these disciplines, puts production issues behind us and develops great operational excellence, we will evolve further and take more cost out of the business in 2019 and beyond. This ends our prepared comments, and we are now ready to address your questions.