George Strickler
Analyst · Robert Kosowsky with Sidoti
Thank you, John. John has reviewed with you our sales for the fourth quarter, the year forecast and the updated forecast for the European market. Our growth has been solid the last 2 years, and is forecast to continue to grow from both a market and our business wins.
Focusing on the profitability for the 2011 fourth quarter and the fourth quarter items affecting net income and earnings per share, as presented in the attached schedule to the earnings, I want to provide detail of the adjustments in the fourth quarter and provide update on the unusual items we have been reporting on quarterly. After reviewing our progress, I will share the operational highlights for the quarter and provide the outlook, including guidance for 2012.
We recorded net income of $38.6 million or $1.56 per share in the fourth quarter. Included in the fourth quarter profitability is a onetime gain from the PST transaction of $1.72 per share, which reflects the valuation increase for our investment in the PST joint venture.
Offsetting the positive impacts in the quarter are 3 key areas which had negative impacts on net income of $11.8 million or earnings per share of $0.48 per share: Costs related to the PST transaction, for transaction costs and adjustment to our long-term incentive plan, which impacted net income by $2.7 million or $0.11 per share. Legacy or previous restructuring activity related to the liquidation of SPL in the U.K., sale of our Sarasota facility and the partial write-down of our ERP project in North America for our North America electronics project, which impacted net income by $4 million or $0.16 per share. Other items reflecting operational impacts were asset valuations and warranty claims, impacting net income by $5.1 million, or $0.21 per share, which also reduced our gross margin by 2.9% of sales in the fourth quarter.
During the third quarter analyst call, we forecasted a gross margin of 21% for the fourth quarter. With the drop in sales of nearly $10 million discussed by John earlier, and the cost items recorded in the fourth quarter, cost of goods sold and gross margin were impacted by 4.3% of sales, which negatively impacted our reported gross margin of 17.4% for the fourth quarter.
With the improvements John discussed, and the improvement in our copper prices and weaker Mexican peso, we should return our gross margins on the Stoneridge base business back to our historical levels of 21% to 23% in 2012.
In the fourth quarter, we finally brought to conclusion some long-term open issues, some of which relate to our 2007 to 2009 restructuring programs, the BCS acquisition we made in October 2009, and a reassessment of our ERP efforts for our North America operations. These items impacted net income by $4 million or $0.16 per share. We recorded $1.1 million in expenses in SG&A for the completion of our restructuring for the Sarasota facility in Florida and our SPL facility in the U.K., which impacted earnings per share by $0.05 per share. We also recognized a write-down of a portion of our goodwill for the acquisition of the BCS business made in October 2009, which resulted in a negative impact to net income of $2.1 million or $0.08 per share.
As the military and defense market has been experiencing a significant reduction in defense spending over the last 2 years, the BCS sales have been negatively impacted, which led to the recording of the partial impairment charge in December of this year. Since Stoneridge owns 51% of the BCS business, our minority partners recognized their 49% share of the non-cash goodwill write-down.
We shut down the Sarasota facility in December 2008, and all production was moved to Lexington, Ohio, and Juarez, Mexico. The final issue to be addressed was the sale of the Sarasota facility. The commercial market has been very depressed in Florida, which extended the period for us to sell the facility. We finally completed the sale of the Sarasota facility in December of this year for about book value, which generated $4 million in cash. At the time of the sale, we increased our environmental reserve by $600,000 to ensure that we provided sufficient reserves to cover future liabilities.
When we shut down our SPL facility in 2008, we worked to cap any liabilities that remained with the company. During the last 3 years, we addressed the wind-down of the company, and took SPL through the U.K. liquidation process. In the fourth quarter, we have successfully liquidated the company and settled all creditor claims and received a full disposition of the pension liability. At this time, we have no defined pension liability programs remaining in the company.
The last remaining issue with SPL is the building, which has a long-term guaranteed lease attached to the facility. We are entering into an agreement that will structure a financial arrangement to cap the liability and provide the owners of the facility and Stoneridge the ability to sublet the facility. We have reserved an additional $500,000 to recognize the potential additional expense for the conditions negotiated in the agreement.
We purchased a 51% interest in Bolton Conductive Systems in October 2009. BCS is a wiring business in the military defense business. We made the purchase to broaden our customer base in military and defense business, to supplement what we do for Navistar with customers such as Force Protection, BAE, AM General, General Dynamics and Oshkosh. Since the acquisition in 2009, military and defense spending has dropped by 60%. As a result, we recorded an impairment of our goodwill by $4.9 million in SG&A, while 49% of this charge, a total of $2.4 million, will be recorded as net income attributable to non-controlling interest, which represents our minority partner share of the goodwill impairment.
As part of the SG&A, we also recognized a write-down of $800,000 for the North America ERP effort that was started in 2008 through 2010 for the North America electronics business. It was stopped in 2011, as we were not satisfied with our ability to implement this project, given the operational issues we were addressing.
We are restarting the ERP project for all of our North America operations, both Control Devices and North America electronics, rather than just our North America electronics business. This effort has been scoped and will focus on demand planning and production forecasting in the first phase in the first half of 2012, which will be completed by the end of the second half of this year.
In addition, we will begin the ERP phase in the second half of 2012, which most likely will extend into the first half of 2014. This effort is important to the continuous improvement of our Wiring business specifically but is also important for standardizing all our operations in North America, similar to what we have in Europe. We believe with the recognition of these charges and expenses in the fourth quarter we have addressed the legacy and previous restructuring programs.
We have right-sized BCS based on the current level of defense spending, and dealt with open items from the operating issues we experienced during 2011. During this past year, we have been reviewing with you the negative cost impacts for operational issues and higher copper prices and the strengthening of the Mexican peso. On the positive side, the Wiring operations have improved significantly during the year, and are positioned well for 2012.
As you recall, the Wiring business was impacted in 2011 by copper increases and the strengthening of the Mexico peso by 10.7 million, and the operational issues cost us $13.3 million due to labor inefficiencies, overtime, excessive headcount, premium freight, and the start-up costs for the new Southwest facility in Saltillo. The operational issues and the currency and commodity impact cost the Wiring business a total of $24 million for the year. For 2012, we have offset much of the negative operating cost of $13.3 million.
Our 2012 performance will be positively impacted by $13.2 million compared to last year. We've reduced the premium freight to normal levels by the end of the second quarter of 2011, and this will benefit us by $5.2 million for both freight-in and freight-out for 2012. The Saltillo plant is running well and the 3.2 startup cost is behind us. In terms of customer deliveries and past due pieces, our operating team in the wiring plants have reduced our past due pieces by 98% for the first quarter of 2012 compared to the first quarter of 2011.
As John discussed, our indirect and direct labor has been reduced in our Wiring operations by 1,075 people from the peak in March 2011 or 17.1%, while sales are up 27.8%. Our sales per employee are up by 29.9%, which is a good measure of productivity improvements. And based on our current plan for 2012, we will continue to improve our indirect and direct labor headcount by an additional reduction of our headcount by 9.7%, while our sales are forecast to increase by 13.7%. As a result, our productivity of sales per employee will increase by 13.9%. Our operating team has made significant progress, which will continue to drive our manufacturing costs lower in 2012.
The other area we have addressed for 2012 is copper escalations and Mexico peso purchases for our Wiring operations. In 2011, we absorbed higher copper cost of $4.4 million, as copper averaged $4.35 per pound during the year. The average price of copper for the year peaked in the first quarter and trended lower during the year. We have had 68% of our estimated consumption for 2012 at $4 per pound. Spot rate is trading between $3.80 to $4 a pound over the last 2 months. This will benefit the Wiring business by about $2 million in 2012 compared to 2011, assuming copper stays at the $4 per pound level throughout this year. The Mexico peso strengthened from MXN 13.83 to U.S. dollar in 2010 to an average of MXN 12.06 to the dollar in 2011.
We purchased about $75 million equivalent during 2011, which cost the Wiring business approximately $6.2 million. For 2012, we are estimating we will purchase $72 million equivalent of Mexico pesos. We've already purchased $55 million at an average price of MXN 13.09 to the dollar. This will benefit the Wiring business by an estimated $5.7 million in 2012 compared to last year, assuming all of the $72 million worth of pesos are repurchased at MXN 13.09.
Through these actions for operational improvement and hedging our copper and the Mexican peso positions for the Wiring business, we'll have offset an estimated $20.9 million of the negative cost impacts of $24 million, which we experienced in 2011. The $24 million cost impacted our gross margin by 3.1%, which lowered our gross margin from a more normal level of 22.3% to 19.2%, which was reported for gross margin for the full year of 2011.
Our biggest accomplishment for the fourth quarter was the completion of the purchase of an additional 24% ownership of PST. We have been working to complete the purchase since the first quarter of last year, and as you remember we started a process to enhance the recognition of the valuation of PST in 2007, and we're prepared to execute an IPO. As reported in December 2011, we purchased an additional ownership position of 24% for $29.7 million in cash and 1.94 million shares of Stoneridge stock.
The transaction generated a onetime gain net of tax of $42.5 million, or $1.72 per share. We incurred transaction fees of $300,000 in the fourth quarter and $849,000 for the full year. In addition, as a result of the transaction we increased our reserve for our long-term incentive plan by $2.4 million. We are excited to increase our stake in PST to 74%. PST will continue to be led by Sergio Leite and a very strong management team.
They continue to work to expand their market presence with car and motorcycle alarms, tracking devices, audio for Fiat and GM and the mass merchandisers, accessories for the dealer and aftermarket and entering the home alarm business in 2012. As Brazil is growing at GNP rates similar to India and China, we will explore ways for Stoneridge to expand our product lines into the fast-growing market in Brazil.
At the same time we are reviewing with PST management what products that could be applied to other global Stoneridge operations especially in India and China. PST's performance continued its improvement in the fourth quarter. John reviewed their sales performance already, but we wanted to review their profitability in the fourth quarter.
PST reported operating income of BRL $24.4 million in the fourth quarter and an operating margin of 21.4% compared to BRL $17 million or 17.1% increase over the fourth quarter of 2010. The fourth quarter operating income was favorably affected by reversal of BRL $9.3 million of value-added tax that had been pending in court actions in Brazil.
The decisions that have been rendered in the courts have supported the position that the value-added tax should not be withheld and would be reversed to PST's financial results. Excluding this reversal, PST would have posted a 13.2% operating margin in the fourth quarter. As we look forward to integrating PST, we will provide guidance and more insight into the business, as PST will be reported as a separate segment.
In 2012, we estimate PST sales will be in the range of BRL $442 million to BRL $497 million, which translates to 240 million to $270 million at our planned exchange rate of 1.84. The real has been trading in the range of 1.85 to 1.75 compared to the dollar during this past month, and we expect PST operating margins to be in the range of 7% to 9% for 2012, which includes expenses for purchase accounting asset write-ups.
The largest expense item in 2012 will be for inventory, which will be amortized primarily in the first half of 2012. The 2011 acquisition of the additional shares of PST included balance sheet write-ups of existing assets as well as recognition of goodwill in relation to the fair value recognized by the purchase. Our earnings guidance for PST for 2012 includes those non-cash expenses associated with the 2011 write-up of assets, which will have a negative impact on profitability.
We expect the expense for the write-off of purchase accounting stepped-up values to be approximately $13.1 million for 2012. The inventory expense is estimated at $5.4 million of the charges, which will be amortized over the first 6 months of this year according to PST's inventory turnover rate. The remaining $7.7 million will be amortized evenly over the entire year. And to clarify timing and amounts, we expect purchase accounting expense to be $9.3 million in the first half of 2012, which will include the full write-off of stepped-up inventory values and $3.8 million in the second half of 2012. And under purchase price accounting, we have up to 1 year to true up asset valuations. In our first quarter update, we will update you on the status of these amounts and timing.
During the fourth quarter, we also extended the term of our existing revolving credit agreement maturity by 5 years. We amended the agreement, which permitted us to complete the PST transaction and modified other accommodating terms. This has allowed us to secure availability under our revolving credit agreement to the year 2016. This follows the successful completion of renegotiating our long-term bonds on October 2010 to extend our maturities to November 2017, and lowering our coupon rate from 11.5% to 9.5%. The bond refinancing also permitted us to complete the secondary share issuance in November 2012, which increased our stock float and availability.
As a result of these activities and our improving financial picture, S&P upgraded our credit rating in May 2011 from B- to BB, and changed our outlook from stable to positive. Moody's upgraded us in December 2011 from B to B1, and improved our outlook from stable to positive.
One very positive metric that results from the transaction and our improving core business performance will be the debt-to-EBITDA ratio. In 2011, Stoneridge's debt to EBITDA, which excluded PST was 5.5x. With the acquisition of PST and based on our guidance for 2012, which includes both PST and Stoneridge, we would improve our debt-to-EBITDA ratio to 2x, a significant improvement from last year's 5.5x, which is a result of improving Stoneridge performance and a positive impact with PST's consolidated results.
With this background, I want to review our operational performance during the fourth quarter. Revenue of $186 million in the fourth quarter of 2011 represents an increase of $25.5 million or 16% over the fourth quarter of 2010. Our sales increase is the result of increasing production volumes in our served markets, new business sales programs, and continued economic improvement in all segments of our markets. For the fourth quarter, our light vehicle sales were $50.2 million, an increase of $600,000 or 1.2%. This increase is attributable to slightly improved volume across all of our markets.
Commercial vehicle production continued strong in North America and was marginal in Western Europe. Our sales in the medium- and heavy-duty truck market was $97.2 million, which was an increase of $15.6 million or 19.2%. The change is primarily a result of increased volume and net new business. And sales to agricultural and other markets totaled $38.7 million, an increase of $9.4 million or 31.9%.
Sales to our top 10 customers grew $20.9 million, a 19.1% improvement over the same period last year. Geographically, our fourth quarter sales allocation changed very little from the previous period of last year. North America accounted for 74% share compared to 73% last year. This percentage will change significantly in 2012 with the acquisition of PST, as none of their sales are in North America. And based on our 2011 sales split, our split would have been 56% in North America, so our business is starting to reflect our significant growth potential in our operations in the emerging markets, Brazil, India and China.
With respect to segment sales, we are experienced growth in both groups for the fourth quarter. Electronic sales were $124.3 million for the period. We added $23.2 million or 22.9% to the top line from improvements in the global, medium- and heavy-duty truck market.
Control Devices sales rose $2.4 million or 4.1% to $61.7 million. Revenue was fueled by the increase in North America commercial vehicle production and strength in the agricultural customer sales for both volume and new business.
Income tax expense for the fourth quarter was $22.7 million on a pre-tax income of $58.1 million. Income tax expense for the year was $26.1 million on a pre-tax income of $71.6 million.
As reported for December 31 of 2010, the company is in a cumulative loss position and continues to provide a valuation allowance, offsetting its federal, state and certain foreign deferred tax assets. As a result, no tax benefit was provided on the U.S. loss for the year. However, the company was required to provide deferred tax expense related to the earnings of our PST joint venture, which is unaffected by our valuation allowance position. The increase in tax expense for 2011 compared to 2010 was primarily attributable to the gain recognized on the write-up, the fair market value of the historic investment in PST.
Excluding the tax and the PST gain, 2011 tax expense increased compared to 2010 due to the decline in performance of our U.S. operations and the impairment of goodwill related to BCS. In addition, 2010 tax expense included a tax benefit for the reversal of a deferred tax liability related to our U.K. operations that was previously included as a component of the accumulated other comprehensive income.
Due to the valuation allowance, the quarterly effective tax rates may fluctuate significantly. Additionally, our annual effective tax rate is unlikely to be in line with the tax rates that we experienced prior to recording the valuation allowance. As previously reported, the company is required to provide U.S. deferred tax expense related to the earnings of PST. For 2012 PST will be a consolidated subsidiary, and as a result we will no longer be required to provide U.S. deferred tax on our share of PST's earnings.
Stoneridge reported fourth quarter net income of $38.6 million or $1.56 per share. This compared with prior year net income of $4.5 million or $0.19 per share. Depreciation expense for the fourth quarter was $4.2 million. Our primary working capital totaled $171.7 million at quarter end, which increased by $82.4 million from the fourth quarter of 2010 levels with inventory accounting for $68.1 million of the increase. Primary reason for the increase in working capital was due to the consolidation of PST at December 31, 2011.
Excluding the effects of the PST consolidation, our primary working capital was $73.8 million or 9.6% of trailing 12 months of sales compared to 14% in the fourth quarter of last year. Current working capital levels for receivables and payables are a function of increasing sales and operational activities. This is slightly better than our $0.12 per dollar sale level and mostly a function of lower inventory levels at year end.
At December 31, 2011, our working capital balance included PST's accounts receivable of $49.2 million, inventory of $58.7 million and accounts payable of $9.9 million. In addition, the inventory contains a write-up of approximately $5.4 million for purchase accounting but is subject to final valuation, which we expect to complete for inventory before the end of June 2012.
PST's business mix is substantially different than Stoneridge as a majority of their sales are in the aftermarket, mass merchandiser and dealer channels. As PST's business mix has more aftermarket, mass merchandiser and retail customers in their distribution channel, they tend to carry more inventory than the Stoneridge core business, which will affect our inventory turns metric in the future. We will provide more detail at the end of the first quarter, as PST will be reported as a separate segment for our first quarter 2012 consolidated results.
Operating cash flow was a source of cash of $18.3 million in the fourth quarter compared to a source of cash of $10.6 million in the fourth quarter of last year. Our cash flow results in the fourth quarter were primarily driven by the decreases in inventory and accounts receivable. Capital investment for the quarter totaled $5.6 million, mainly reflecting investment in new products in the Wiring operation and Control Device segment. For the year, capital expenditures were $26.3 million, which included $5.2 million for the new Saltillo facility in Mexico.
As of December 31, 2011, we have $30 million of availability under our $100 million asset-based lending facility. The balance includes $38 million of which part was used for our PST acquisition. Excluding the drawn balance, we would have had $77.5 million in undrawn availability at year end, which is a $16.2 million increase over the same period last year. Our fourth quarter ending cash balance totaled $78.8 million compared with $72 million at the end of the fourth quarter of last year, which contained approximately $20 million that was dispersed on January 5, 2012, as part of the PST transaction.
And going forward, we expect we will continue to fund our operational growth initiatives mostly through our free cash flow generation and available cash balances. And we believe we will pay off our borrowed ABL balance by the end of 2012.
Our business continues to show significant growth as the market remains strong for the North American, European commercial market, and Ag continues its strength. John shared with you how we are addressing customer service levels for the Wiring business, which are significantly better than our performance in the first 2 quarters of 2011. And as a result, we've been able to reduce premium freight and other labor and overhead cost to a more normal levels. We have made progress in our labor efficiencies and shared our programs to further reduce headcount by 9.7% in 2012, while sales are forecast to grow by 13.7%, and sales per employee will increase by 13.9% for the Wiring business. We will benefit from improved copper cost and a weaker Mexico peso as we have hedge contracts in place and should benefit 2012 compared to 2011.
We are working to improve our cash flow position with profitability and the reduction of our inventory as the primary contributors. We have extended our ABL by 5 years with attractive rates and favorable terms, which will secure our debt and loan availability under a revolving credit agreement. Our financial and operational performance has been improving compared to where it began in the beginning of last year, and we need to continue to accelerate the improvement of our operating shortfalls for the Wiring business by ensuring that the improvements are sustainable as we continue to grow.
As we look to 2012, we believe Stoneridge's core business sales, which exclude the PST consolidated sales, will be in the range of $820 million to $850 million, and our core gross margins will exclude any effects of the PST consolidation, will be in the range of 21% to 23%, and operating income will be in the range of 5.5% to 6.5%. PST's 2012 sales will be in the range of $240 million to $270 million based on a average exchange rate of 1.84 to the U.S. dollar, which we are using for planning purposes.
We expect gross margins to be in the range of 40% to 43%, which includes expensing a non-cash inventory write-up estimated at $5.4 million, which will be expensed in the first 6 months of 2012, and $1.5 million for the step-up of other assets included in cost of goods sold. PST's SG&A will include a non-cash expense of $6.2 million for the write-up of assets, which will be amortized evenly by month over the year.
The adjustments of purchase accounting will be tax affected with a resilient statutory rate of 34%, and the after-tax gross amount will be shared with our minority partners for their 26% ownership, and will be reflected in the P&L in non-controlling interest line. Consolidated Stoneridge, including PST results, will reflect a range of sales from $1,060,000,000 to $1,120,000,000 range, which is the first time we'll exceed $1 billion in sales.
The forecasted gross margin will run in the range of 25.5% to 27.5%, and operating income will range from 6% to 7%. Based on our sales growth and margin improvement, we believe our full year 2012 earnings per share will be in the range of $1.10 to $1.30 per share.
With that, operator, I would like to open up the call for questions.