George Strickler
Analyst · KeyBanc
Thank you, John. As we've been sharing with you over the past several quarters. We have been addressing our 2011 operating issues and wiring business. Based on our teams' efforts, we expect to improve financial performance in 2012. In our last call, we shared with you that our first quarter is progressing consistent with our plans.
We're pleased that our first quarter was consistent with our plans. We benefited from improved operating performance in the wiring business along with more favorable copper cost and improved Mexico peso exchange rates from a weaker Mexican peso of which is partially offset by increased raw material cost.
Raw material cost increases to net sales continue to be an area we're working to address, as our raw materials to sales in the first quarter 2012 was 2.2% higher than the first quarter of last year. We're working to address the raw material cost increases through pricing actions, redesigns of our products collaborating with our suppliers and pursuing our older net materials source, part of our raw material cost, percentages of net sales increases just due to product and customer mix in our controlled device segment.
We've also been pleased with the progress integrating PST into Stoneridge after completing the final phase of the transaction on January 5, 2012. Last year, we reviewed with you quarterly the negative cost impacts for operational issues, higher copper prices, the financial impact of the Mexico peso and the startup of our new facility in Saltillo, Mexico.
As a result of the actions has taken the wiring operations improved significantly during 2011 and is well-positioned for this year. We saw the improvement in our financial and operating results as gross margins return to more levels in the first quarter. As you recall, the wiring business was adversely impacted in 2011 by operational issues, which causes $13.3 million, the laboring efficiency, over time, excess of headcount, premium freight and the startup cost of our new facility.
In addition, the wiring business was adversely impacted in 2011 by copper increases and the strength in the Mexico peso by $10.7 million. The operational issues and the currency and commodity impact cost for wiring business, it total $24 million last year.
For 2012, we have offset and estimated $20.9 million of the $24 million of the negative operating cost, commodity impacts and foreign exchange costs. And our plan for this year was to offset $13.2 million of the operating issues, which will positively impact 2012.
We have 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 the freight-in and the freight-out for this year. In the first quarter 2011, premium freight in wiring operations improved by $3 million compared to last year. The Saltillo plant is running well and the $3.2 million startup cost is behind us.
In regarding commodities, we have had 68% of our estimated copper consumption for this year at $4 per pound. And this will benefit the wiring business by about 2 million in 2012 compared to 2011, assuming copper's stays at $4 per pound or lower for the remainder of the year.
We have executed a forward contract to purchase $55 million of Mexico pesos at an average exchange rate of $13.09 Mexico pesos to the U.S. dollar. This will benefit the wiring business by an estimated $5.7 million in 2012 compared to last year, assuming the $72 million worth of peso equivalent can be purchased at Mexico pesos $13.09 to the U.S. dollar.
Through the actions taken to improve operations and hedging our copper in the Mexico peso positions for the wiring business, we will offset nearly $20.9 million in negative cost impacts $24 million which we experienced last year. As a direct result of these improvements for first quarter of 2012, our gross profit excluding PST was 21.3% and is in line with plan and our guidance.
We increased our ownership stake to 74% of PST as of December 31, and fully completed the transaction on January 5 of this year. As a result of the 24% ownership purchase, this will change the accounting for PST's results other financial statement.
Last year, we've recognized 50% of PST's net income under the equity method of accounting in our P&L. And a single line called equity and investee. With the additional ownership in PST as of December 31, of last year, we fully consolidated PST's balance sheet and our yearend balance sheet.
Starting January 1, of this year, in addition to consolidating the balance sheet, we will recognize a 100% of PST's revenues, expenses and net income in our P&L. And we'll recognize an expense for 26% minority partner share of net income as non-controlling interest expense. In terms of taxes, we will only reflect PST's effective tax rate in our consolidated results, which tend to vary between 19% and 20% on PST's pre-tax income.
At the time, we'll receive dividends which normally is in the fourth quarter, we will accrue additional tax between the U.S. statutory tax rate of 35% and the effective rate of tax provided in Brazil on the cash dividend amount being received by Stoneridge. PST will be representing our SEC filings as a separate reporting segments starting with the first quarter of this year. The 2011 acquisition of the additional shares of PST included balance sheet write-ups of the existing assets as well as recognition and good-will in relation, of the fair value recognize by the purchase.
Our 2012 earnings guidance included those non-cash expenses associated with the 2011 write-up of assets which have a negative impact on profitability for PST. And our 2012 guidance, we expected the expense for the write-off of purchase account stepped-up values to be approximately $13.1 million for 2012.
The inventory expense was estimated $5.4 million, which would be amortized over the first 5 months of this year according to PST's inventory turnover rate. The remaining $7.7 million was the amortized evenly over the entire year.
In terms of timing and amounts we expect that purchase accounting expense to be $9.3 million in the first half of this year, which would include the full write-off of stepped-up inventory values of $5.4 million. And $7.7 million for all other assets and $3.8 million in the second half of 2011 as inventory write-ups will be amortized in the first half of this year.
Under purchase price accounting, we have up to one year to true up asset valuations. And we have continued to refine our estimates for purchase accounting amounts that affects PST's profitability.
In the first quarter, we expensed $3.2 million in non-cash purchase accounting adjustments in total. This had a net income impact of $1.6 million or $0.06 per share. As a result of our EPS excluding purchase prices accounting adjustments would have been $0.28 per share for continuing operations.
This includes $1.8 million for the write-up of inventory and the remaining $1.4 million of expense for all other asset write-ups. For the balance of the year, we expect another $1.5 million of expense for inventory and $5.2 million for other asset write-ups. We expect the $1.5 million for inventory to be expense for the second quarter, while the other $5.2 million will be expense radically over the balance of the year.
And in summary, total purchase accounting adjustments in 2012 are now expected to be $9.9 million compared to $13.1 million in our previous guidance. Of the $9.9 million of purchase accounting, that will affect net income $1.5 million is depreciation and $6.7 million is the amortization.
In addition of the normal translation risk of operating results associated with the foreign subsidiary, PSTs had significant risk associated with foreign exchange that can affect if some Stoneridge's financial results. PST currently have the U.S. dollar balance sheet exposure of $23 million and U.S. dollar denominated debt with 2 Brazilian banks, which we're used to finance Chinese U.S. dollar supplier payments for the launch of their audio products and $3 million for monthly U.S. dollar denominated payables.
These exposures are revalued each month end with the changes in the value reflected through the balance sheet in the P&L. These valuation differences could be large and affect PSTs profitability from month-to-month, mitigate this risk we've embarked an inventory reduction plan to reduce PSTs debt as it is the least expensive way to reduce the U.S. dollar exposure.
PST has U.S. dollar denominated direct material disbursements source from China with an estimated annual spend amount of approximately $45 million. If the U.S. dollar strengthens against the Brazilian real then the cost of these goods for currency or loan can significantly affect the gross profit of PST.
And since the first of the year the, real revalued to 74 in January, but weakened to 182 by the end of March. Since the first quarter close the real exchange rates weakened compare to the U.S. dollar to 189, which will be used for April 30 to close. At the exchange rate of 189, this represents a devaluation of an additional 5.2% in the month of April that would represent nearly $1.2 million PNL charge if the exchange rates stays at the same level of years at the end of April. PST is working to reduce their inventories over $20 million, significantly reduced the U.S. dollar payable exposure by paying down U.S. dollar debt and expense of local currency working capital loans.
Now I want to review our operational performance during the first quarter. Revenue up $262.3 million in the first quarter of 2012, represents an increase of $69.2 million or 35.9% over the first quarter of last year. Our first quarter sales include $53.7 million of PST sales that were not consolidated last year. Excluding PSTs first quarter sales, Stoneridge's quarter sales increased by $15.6 million or 8.1% compared to the first quarter of last year. Stoneridge's core sales increased as the result of increasing production volumes in most of our served markets, new business sales programs and continued economic improvement in most segments of our markets.
For the first quarter of pass car/light vehicle sales were $55.1 million and a body equal to the first quarter of last year. We did not experience the market growth at other automotive suppliers, they're reporting as we've been realigning our automotive product portfolio around key product families in emissions and actuations which have attracted market growth while reducing our presence in commodity or noncompetitive product lines.
Commercial vehicle production continued strong in North America and was down in Western Europe. Our sales in the medium and heavy-duty truck market was $104.4 million which was an increase of $7.8 million or 8.1%. The change is primarily a result of increased volume in the North America market and net new business.
Sales to ag and other market totaled $49.1 million, an increase of $7.8 million or 19%. And sales to our top 10 customers grew by $6.4 million, a 4.5% improvement over the same period last year.
Geographically our sales allocation shifted with the consolidation of PST. The PST, our sales allocation as approximately 61% for North America, 21% South America, 16% in Europe and 2% other. And excluding PST, North America accounted for 74% share compared to 77% for the same quarter last year.
With respect to segment sales, we experienced growth in both groups for the first quarter. Electronics sales were $138.2 million for the period. We added $13.4 million or 10.7% to the top line from improvements in the global ag and other category as well as medium and heavy-duty truck market.
Controlled devices rose $2.2 million or 3.2% to $78.4 million and revenue was fueled mainly by the increase in North America commercial vehicle production and strengthening of ag and pass car.
Stoneridge reported a first quarter 2012 consolidated gross margin of 24.8% which includes the results of PST. The Stoneridge core business which excludes the results of PST reported gross margin of 21.3% which compares favorably to our gross margin in the first quarter of last year of 20.4% and is back on our guidance range of 21% to 23%.
And as discussed earlier, our first quarter 2012 core gross margin was driven by improvement in labor productivity and premium freight primarily in our North America wiring business and improvements in copper cost and the weakening in the Mexico peso. The improvement in labor productivity and premium freight that positively affected gross margin totaled $5.1 million, the decreases in copper cost and weakening of the Mexico peso positively impacted in our results by approximately $1 million and $0.50 million respectively.
We continue to execute plans including reducing direct labor and indirect labor, reducing overtime developing more efficient manufacturing processes to reduce turnover of people and enhance our training programs to prove our operating efficiencies. These actions have reduced and will continue to reduce our manufacturing cost.
Additionally, during the first quarter of this year we have experienced higher raw material cost related to the precious metals, rarer magnets and resins primarily consumed in our controlled devices segment. Control devices has been implementing price increases to offset these cost increases, which will start to be reflected in the second quarter of this year.
Income tax expense for the first quarter was $1.2 million and pre-tax income of $7 million resulting in an effective tax rate of 17.5%. As reported for December 31 of last year, the company continues to provide evaluation allowance offsetting its federal, state and certain foreign deferred tax assets.
The decrease in the effective tax rate for the 3 month ended March 31 of this year, compared to the same period for last year was attributable to the improved financial performance of the U.S. operations as well as the consolidation of PST.
As previously mentioned for 2012, PST has a consolidated subsidiary as a result, we are no longer required revive U.S. deferred tax expense on our share of PST's earnings. We expect the 2012 annual effective tax rate to be between 16% and 20%. And we anticipate cash taxes be between $7.5 million and $8.5 million all related to foreign and state taxes.
Stoneridge reported first quarter net income of $5.8 million or $0.22 per share and this compared with last year net income of $2.9 million or $0.12 per share.
Depreciation and amortization expense for the first quarter was $8.8 million, an increase of $3.8 million compared to the first quarter of last year. The increase is due primarily to consolidation of PST's results in 2012. PST's depreciation and amortization on an annual basis is expected to be approximately $18 million. And Stoneridge core to be approximately $20 million.
Our primary working capital totaled $210 million at quarter end, which increased by $99.2 million from the first quarter of 2011 levels. The primary reason for the increase in working capital was due to the consolidation of PST in the Stoneridge at December 31 and March 31, 2012 balance sheets. Excluding the effects of the PST consolidation, Stoneridge's primary working capital was $122.8 million or $12 million higher than the first quarter of last year.
Current working capital levels for inventory, receivables and payables are a function of increasing sales and operational activities. PST's inventory continue to write-up of approximately $5.4 million at December 31 of last year and $1.5 million of March 31 of this year for purchase accounting, but is subject to final evaluation, which we expect to complete before the end of June of this year If there is any difference, we expect to report this in the second quarter of this year.
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. Operating cash flow was a sourced cash of $5.9 million in the first quarter compared to the use of cash of $15.5 million in the first quarter of last year. Our cash flow results in the first quarter were primarily driven by the higher net income and lower capital expenditures which was offset by higher trade receivables to fund higher sales.
Capital investment for the quarter totaled $6.8 million, mainly reflecting investment in new products in the wiring operation and control device segment. Capital expenditures for PST totaled $2.4 million, mainly for the capitalization of tracking devices which are rented to subscribers and are included in the monthly fees charge to the subscribers.
The PST's tracking device business, they have historically sold their tracking devices to their subscribers. The upfront cost was limiting the growth of adding new subscribers for their tracking service business. As a result, PST now purchases tracking devices which is included in their annual capital expenditures and represents nearly 50% of the annual capital.
PST recovers the cost of the tracking devices by charging the tracking device, covering a service fee to the subscribers through this part of the contract. As of March 31, we have $63 million of availability under our $100 million asset base lending facility. And the balance of that drawn debt against our credit line includes $31 million, a portion of which was used for PST acquisition.
PST has several loans used to finance working capital totaling $47.2 million of which $36.5 million is current. And PST is in full compliance for our covenants. Our first quarter ending cash balance totaled $42.9 million compared to $78.7 million at the end of the first quarter of last year.
In going forward, we expect we will continue to fund our operational growth initiatives mostly through our free cash flow generation and available cash balances. We believe we will pay off our borrowed ABL balance by the end of 2012. Our forecasts are for PST to pay down $19 million of their working capital debt and US$20 million loans by the end of this year.
Our business continues to show growth as the market remains strong for the North America pass car and light vehicle, North America commercial and Ag sectors. John shared with you how we have addressed customer service levels and operating issues for the wiring business. Our quarter-on-quarter performance demonstrates the improvement. We've made progress improving our labor efficiencies and continue to reduce headcount in 2012 to further improve our labor efficiencies. The wiring business sales are forecast to grow by 9.8% while sales per employee will increase by 30% on the year-on-year basis.
We will benefit from improved copper cost and a weaker Mexico peso exchange rate as we have hedged contracts in place, which should benefit 2012, compared to 2011. We are working to improve our cash flow position with profitability and the reduction of our inventories of primary contributors. Our financial and operational performance has been improving compared to 2011 and we continue to accelerate the improvement of our operating shortfalls from the wiring business by ensuring that the improvements are sustainable as we continue to grow.
As we look through 2012, we've maintained our belief that Stoneridge's core business sales which exclude the PST consolidated sales would be in the range of $820 million to $850 million and core gross margins were exclude any effects of the PST consolidation will be in the range of 21% to 23% and core operating income will be in the range of 5.5% to 6.5%.
PSTs 2012 sales would be in the range of $240 million to $270 million based on exchange rate of $184 which were used for planning purposes. We expect gross margins to be in the range of 40% to 43% which includes expensing all the non-cash purchase accounting asset write-ups. The non-cash purchase accounting guidance including non-cash inventory write-up, now estimated at $1.4 million which will be expensed in the second quarter of the year and $1.1 million for the step-up of other assets that will be amortized in the last 3 quarters of the year.
PSTs SG&A including non cash expense of $4.1 million of the write-up of assets which will be amortized evenly by month over the balance of the year. The adjustments of purchase accounting would be tax affected with the Brazilian statutory rate of 34%, the after tax gross amount would be shared with our minority partners with their 26% ownership and will be reflected in the P&L and the non-controlling interest line.
The consolidated Stoneridge, we are reaffirming our guidance which including PSTs results, reflecting range of net sales from $1.060 billion to $1.120 billion range which is the first time will exceed $1 billion in sales.
The forecasted gross margins will run in the range of 25.5% to 27.5% and operating income would be in the range from 6% to 7%. And 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.
Operator, now I would like to open up the call for any questions.