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1. SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES
Principles of Consolidation – The consolidated financial statements include the accounts of Greatbatch, Inc. and its wholly owned subsidiary Greatbatch Ltd. (collectively, the “Company” or “Greatbatch”). All intercompany balances and transactions have been eliminated in consolidation.
Nature of Operations – The Company operates its business in two reportable segments – Greatbatch Medical and Electrochem Solutions (“Electrochem”). The Company's customers include large multi-national original equipment manufacturers (“OEMs”). The Greatbatch Medical segment designs and manufactures medical devices and components primarily for the Cardiac Rhythm Management (“CRM”), Neuromodulation, Vascular Access and Orthopaedic markets. Additionally, Greatbatch Medical offers value-added assembly and design engineering services for products that incorporate Greatbatch Medical components. As a result of the strategy put in place over three years ago, Greatbatch Medical now offers its customers complete medical devices including design, development, manufacturing, regulatory submission and supporting worldwide distribution. This medical device strategy is being facilitated through the QiG Group and leverages the component technology of Greatbatch Medical and Electrochem in the Company's core markets: Cardiovascular, Neuromodulation and Orthopaedic. Once the QiG Group designs and develops a medical device, it is manufactured by Greatbatch Medical. The operating expenses (RD&E, SG&A) of the QiG Group are included within the Greatbatch Medical segment.
Electrochem provides technology solutions where safety, reliability, quality and durability are critical. Electrochem's customized primary (non-rechargeable) and secondary (rechargeable) battery solutions are used in markets such as energy, portable medical, military, environmental and more. Electrochem's product lines cover a number of highly-customized battery-powered applications in remote and demanding environments, including down hole drilling tools, military communication devices, automated external defibrillators, oceanographic buoys and more. Electrochem's primary and secondary power solutions and wireless sensing systems are used in markets where failure is not an option.
Fiscal Year End – The Company utilizes a fifty-two, fifty-three week fiscal year ending on the Friday nearest December 31st. Fiscal years 2011, 2010 and 2009 ended on December 30, 2011, December 31, 2010 and January 1, 2010, respectively. Fiscal years 2011, 2010 and 2009 all contained fifty-two weeks.
Fair Value Measurements – Fair value is defined as the price that would be received to sell an asset or paid to transfer a liability (i.e. the “exit price”) in an orderly transaction between market participants at the measurement date. Accounting Standards Codification (“ASC”) establishes a hierarchy for inputs used in measuring fair value that maximizes the use of observable inputs and minimizes the use of unobservable inputs by requiring that the most observable inputs be used when available. Observable inputs are inputs that market participants would use in pricing the asset or liability developed based on market data obtained from sources independent of the Company. Unobservable inputs are inputs that reflect the Company's assumptions about the assumptions market participants would use in pricing the asset or liability developed based on the best information available in the circumstances. The hierarchy is broken down into three levels based on the reliability of inputs as follows:
Level 1 — Valuation is based on quoted prices in active markets for identical assets or liabilities that the Company has the ability to access. Level 1 valuations do not entail a significant degree of judgment.
Level 2 — Valuation is determined from quoted prices for similar assets or liabilities in active markets, quoted prices for identical instruments in markets that are not active or by model-based techniques in which all significant inputs are observable in the market.
Level 3 — Valuation is based on unobservable inputs that are significant to the overall fair value measurement. The degree of judgment in determining fair value is greatest for Level 3 valuations.
The availability of observable inputs can vary and is affected by a wide variety of factors, including, the type of asset/liability, whether the asset/liability is established in the marketplace, and other characteristics particular to the valuation. To the extent that a valuation is based on models or inputs that are less observable or unobservable in the market, the determination of fair value requires more judgment. In certain cases, the inputs used to measure fair value may fall into different levels of the fair value hierarchy. In such cases, for disclosure purposes the level in the fair value hierarchy within which the fair value measurement in its entirety falls is determined based on the lowest level input that is significant to the fair value measurement in its entirety.
Fair value is a market-based measure considered from the perspective of a market participant rather than an entity-specific measure. Therefore, even when market assumptions are not readily available, assumptions are required to reflect those that market participants would use in pricing the asset or liability at the measurement date.
The carrying amount of cash and cash equivalents, trade receivables and accounts payable, approximated their fair value as of December 30, 2011 based upon the short-term nature of these instruments. Note 17 “Fair Value Measurements” contains additional information on assets and liabilities recorded at fair value in the consolidated financial statements.
Cash and Cash Equivalents – Cash and cash equivalents consist of cash and highly liquid, short-term investments with maturities at the time of purchase of three months or less.
Concentration of Credit Risk – Financial instruments that potentially subject the Company to concentration of credit risk consist principally of accounts receivable. A significant portion of the Company's sales are to four customers, all in the medical device industry, and, as such, the Company is directly affected by the condition of those customers and that industry. However, the credit risk associated with trade receivables is partially mitigated due to the stability of those customers. The Company performs on-going credit evaluations of its customers. Note 19 “Business Segment, Geographic and Concentration Risk Information” contains information on sales and accounts receivable for these customers. The Company maintains cash deposits with major banks, which from time to time may exceed insured limits. The Company performs on-going credit evaluations of its banks.
Allowance for Doubtful Accounts – The Company provides credit, in the normal course of business, to its customers in the form of trade receivables. Credit is extended based on evaluation of a customer's financial condition and collateral is not required. The Company maintains an allowance for those customer receivables that it does not expect to collect. The Company accrues its estimated losses from uncollectable accounts receivable to the allowance based upon recent historical experience, the length of time the receivable has been outstanding and other specific information as it becomes available. Provisions to the allowance for doubtful accounts are charged to current operating expenses. Actual losses are charged against this allowance when incurred.
Inventories – Inventories are stated at the lower of cost, determined using the first-in first-out method, or market. Write-downs for excess, obsolete or expired inventory are based primarily on how long the inventory has been held as well as our estimates of forecasted net sales of that product. A significant change in the timing or level of demand for our products may result in recording additional write-downs for excess, obsolete or expired inventory in the future. Note 4 “Inventories” contains additional information on the Company's inventory.
Property, Plant and Equipment – Property, plant and equipment is carried at cost less accumulated depreciation. Depreciation is computed by the straight-line method over the estimated useful lives of the assets, as follows: buildings and building improvements 7-40 years; machinery and equipment 3-8 years; office equipment 3-10 years; and leasehold improvements over the remaining lives of the improvements or the lease term, if less. The cost of repairs and maintenance are expensed as incurred; renewals and betterments are capitalized. Upon retirement or sale of an asset, its cost and related accumulated depreciation or amortization is removed from the accounts and any gain or loss is recorded in operating income or expense. Note 5 “Property, Plant and Equipment” contains additional information on the Company's property, plant and equipment.
Business Combinations – The Company records its business combinations under the acquisition method of accounting. Under the acquisition method of accounting, the Company allocates the purchase price of each acquisition to the tangible and identifiable intangible assets acquired and liabilities assumed based on their respective fair values at the date of acquisition. The fair value of identifiable intangible assets is based upon detailed valuations that use various assumptions made by management. Any excess of the purchase price over the fair value of net tangible and identifiable intangible assets acquired is allocated to goodwill. All direct acquisition-related costs are expensed as incurred. Note 2 “Acquisitions” contains additional information on the Company's acquisitions.
Amortizing Intangible Assets – Amortizing intangible assets consists primarily of purchased technology, patents and customer lists. The Company amortizes its definite-lived intangible assets over their estimated useful lives utilizing an accelerated or straight-line method of amortization, which approximates the projected distribution of cash flows used to fair value those intangible assets at the time of acquisition. When the straight-line method of amortization is utilized, the estimated useful life of the intangible asset is shortened to assure that recognition of amortization expense corresponds with the distribution of expected cash flows. The amortization period for the Company's amortizing intangible assets are as follows: purchased technology and patents 5-15 years; customer lists 7-20 years and other intangible assets 1-10 years. Note 6 “Intangible Assets” contains additional information on the Company's amortizing intangible assets.
Impairment of Long-Lived Assets – The Company assesses the impairment of definite-lived long-lived assets or asset groups when events or changes in circumstances indicate that the carrying value may not be recoverable. Factors that are considered in deciding when to perform an impairment review include: A significant decrease in the market price of the asset or asset group; A significant change in the extent or manner in which a long-lived asset or asset group is being used or in its physical condition; A significant change in legal factors or in the business climate that could affect the value of a long-lived asset (asset group), including an action or assessment by a regulator; An accumulation of costs significantly in excess of the amount originally expected for the acquisition or construction; A current-period operating or cash flow loss combined with a history of operating or cash flow losses or a projection or forecast that demonstrates continuing losses associated with the use of a long-lived asset or asset group; or a current expectation that, more likely than not, a long-lived asset or asset group will be sold or otherwise disposed of significantly before the end of its previously estimated useful life. The term more likely than not refers to a level of likelihood that is more than 50 percent.
Potential recoverability is measured by comparing the carrying amount of the asset or asset group to its related total future undiscounted cash flows. If the carrying value is not recoverable, the asset or asset group is considered to be impaired. Impairment is measured by comparing the asset or asset group's carrying amount to its fair value. When it is determined that useful lives of assets are shorter than originally estimated, and no impairment is present, the rate of depreciation is accelerated in order to fully depreciate the assets over their new shorter useful lives.
Goodwill and certain trademarks and tradenames recorded are not amortized but are periodically tested for impairment. The Company assesses goodwill for impairment by comparing the fair value of its reporting units to their carrying amounts on the last day of each fiscal year, or more frequently if certain events occur as described above. If the fair value of a reporting unit is less than its carrying value, an impairment loss is recorded to the extent that the implied fair value of the goodwill within the reporting unit is less than its carrying value. Fair values for reporting units are determined based on discounted cash flows and market multiples. Indefinite lived intangible assets are assessed for impairment on the last day of each fiscal year, or more frequently if certain events occur as described above, by comparing the fair value of the intangible asset to its carrying value. The fair value is determined by using a relief-from-royalty approach.
The Company has determined that, based on the impairment tests performed, no impairment of goodwill has occurred during 2011, 2010 and 2009. During 2009, the Company recognized a $15.9 million impairment charge related to its trademarks and tradenames. No impairment of the Company's trademarks and tradenames occurred during 2011 or 2010. Note 6 “Intangible Assets” contains additional information on the Company's intangible assets.
Other Long-Term Assets – Other long-term assets includes deferred fees incurred in connection with the Company's issuance of its convertible subordinated notes and revolving line of credit. These fees are amortized to Interest Expense using the effective interest method over the period from the date of issuance to the put option date (if applicable) or the contractual maturity date, whichever is earlier. The amortization of deferred fees is included in Depreciation and Amortization in the Consolidated Statements of Cash Flows. Note 8 “Debt” contains additional information on the Company's deferred financing fees.
Other long-term assets also include investments in equity securities of entities which the Company does not have the ability to exercise significant influence over and are accounted for using the cost method. Each reporting period, management evaluates these investments to determine if there are any events or circumstances that are likely to have a significant effect on the fair value of the investment. Examples of such impairment indicators include, but are not limited to: a recent sale or offering of similar shares of the investment at a price below the Company's cost basis; a significant deterioration in earnings performance; a significant change in the regulatory, economic or technological environment of the investee; or a significant doubt about an investee's ability to continue as a going concern. If an impairment indicator is identified, management will estimate the fair value of the investment and compare it to its carrying value. The estimation of fair value considers all available financial information related to the investee, including, but not limited to, valuations based on recent third-party equity investments in the investee. If the fair value of the investment is less than its carrying value, the investment is impaired and a determination as to whether the impairment is other-than-temporary is made. Impairment is deemed to be other-than-temporary unless the Company has the ability and intent to hold the investment for a period sufficient for a market recovery up to the carrying value of the investment. Further, evidence must indicate that the carrying value of the investment is recoverable within a reasonable period. For other-than-temporary impairments, an impairment loss is recognized equal to the difference between the investment's carrying value and its fair value. The Company has determined that these investments are not considered variable interest entities. The Company's exposure related to these entities is limited to its recorded investment. These investments are in start-up research and development companies whose fair value is highly subjective in nature and subject to future fluctuations, which could be significant.
Income Taxes – The consolidated financial statements of the Company have been prepared using the asset and liability approach in accounting for income taxes, which requires the recognition of deferred income taxes for the expected future tax consequences of net operating losses, credits, and temporary differences between the financial statement carrying amounts and the tax bases of assets and liabilities. A valuation allowance is provided on deferred tax assets if it is determined that it is more likely than not that the asset will not be realized.
It is the policy of the Company not to provide deferred taxes on the excess of the amount for financial reporting over the tax basis of the investment in its European subsidiaries that is essentially permanent in duration. This outside basis difference of approximately $7.0 million as of December 30, 2011, which is primarily attributable to cumulative translation adjustments, and associated unrecognized deferred tax liability, would only become taxable on the sale of these subsidiaries.
The Company accounts for uncertain tax positions using a more likely than not recognition threshold. The evaluation of uncertain tax positions is based on factors including, but not limited to, changes in tax law, the measurement of tax positions taken or expected to be taken in tax returns, the effective settlement of matters subject to audit, new audit activity and changes in facts or circumstances related to a tax position. These tax positions are evaluated on a quarterly basis. The Company recognizes interest expense related to uncertain tax positions as Interest Expense. Penalties, if incurred, are recognized as a component of Selling, General and Administrative Expenses (“SG&A”).
The Company and its subsidiary file a consolidated U.S. federal income tax return. State tax returns are filed on a combined or separate basis depending on the applicable laws in the jurisdictions where tax returns are filed. The Company also files foreign tax returns on a separate company basis in the countries in which it operates. See Note 13 “Income Taxes” for additional information.
Convertible Subordinated Notes – For convertible debt instruments that may be settled in cash upon conversion, the Company accounts for the liability and equity components of those instruments in a manner that will reflect the entity's nonconvertible debt borrowing rate when interest cost is recognized in subsequent periods.
Upon issuance, the Company determined the carrying amount of the liability component of CSN by measuring the fair value of a similar liability that does not have the associated conversion option. The carrying amount of the conversion option was then determined by deducting the fair value of the liability component from the initial proceeds received from the issuance of CSN.
The carrying amount of the conversion option was recorded in Additional Paid-In Capital with an offset to Long-Term Debt and is being amortized using the effective interest method over the period from the date of issuance to the contractual maturity date. Deferred financing fees incurred in connection with the issuance of CSN, were allocated proportionally to the proceeds of the liability and equity components. The deferred financing fees allocated to the debt component are being amortized using the effective interest method over the period from the date of issuance to contractual maturity date. The deferred financing fees allocated to the equity component were recorded as an offset to Additional Paid-In Capital. The amortization of discount and deferred fees related to the Company's convertible debt instruments is included in Depreciation and Amortization in the Consolidated Statements of Cash Flows. See Note 8 “Debt” for additional information.
Derivative Financial Instruments – The Company recognizes all derivative financial instruments in its consolidated financial statements at fair value. Changes in the fair value of derivative instruments are recorded in earnings unless hedge accounting criteria are met. The Company designates its interest rate swaps (See Note 8) and foreign currency contracts (See Note 14) entered into as cash flow hedges. The effective portion of the changes in fair value of these cash flow hedges is recorded each period, net of tax, in Accumulated Other Comprehensive Income until the related hedged transaction occurs. Any ineffective portion of the changes in fair value of these cash flow hedges is recorded in earnings. In the event the hedged cash flow for forecasted transactions does not occur, or it becomes probable that they will not occur, the Company would reclassify the amount of any gain or loss on the related cash flow hedge to income (expense) at that time. Cash flows related to these derivative financial instruments are included in cash flows from operating activities.
Revenue Recognition – The Company recognizes revenue when it is realized or realizable and earned. This occurs when persuasive evidence of an arrangement exists, delivery has occurred, the price is fixed or determinable, the buyer is obligated to pay us (i.e., not contingent on a future event), the risk of loss is transferred, there is no obligation of future performance, collectability is reasonably assured and the amount of future returns can reasonably be estimated. With regards to the Company's customers (including distributors), those criteria are met at the time of shipment when title passes. The Company includes shipping and handling fees billed to customers in Sales. Shipping and handling costs associated with inbound and outbound freight are recorded in Cost of Sales. In certain instances the Company obtains component parts for sub-assemblies from its customers that are included in the final product. These amounts were excluded from Sales and Cost of Sales recognized by the Company. The cost of these customer supplied component parts amounted to $27.9 million, $29.9 million and $27.8 million in 2011, 2010 and 2009, respectively.
Product Warranties – The Company allows customers to return defective or damaged products for credit, replacement, or exchange. The Company warrants that its products will meet customer specifications and will be free from defects in materials and workmanship. The Company accrues its estimated exposure to warranty claims, through Cost of Sales, based upon recent historical experience and other specific information as it becomes available. Note 14 “Commitments and Contingencies” contains additional information on the Company's product warranties.
Research, Development and Engineering Costs, Net – Research, development and engineering (“RD&E”) costs are expensed as incurred. The primary costs are salary and benefits for personnel, material costs used in development projects and subcontracting costs. Cost reimbursements for engineering services from customers for whom the Company designs products are recorded as an offset to engineering costs upon achieving development milestones specified in the contracts. Note 11 “Research, Development and Engineering Costs, Net” contains additional information on the Company's RD&E activities.
Stock-Based Compensation – The Company records compensation costs related to stock-based awards granted to employees based upon their estimated fair value on the grant date. Compensation cost for service-based awards is recognized ratably over the applicable vesting period. Compensation cost for nonmarket-based performance awards is reassessed each period and recognized based upon the probability that the performance targets will be achieved. Compensation cost for market-based performance awards is expensed ratably over the applicable vesting period and is recognized each period whether the performance metrics are achieved or not.
The Company utilizes the Black-Scholes option pricing model to estimate the fair value of stock options granted. For service-based and nonmarket-based performance restricted stock and restricted stock unit awards, the fair market value of the award is determined based upon the closing value of the Company's stock price on the grant date. For market-based performance restricted stock unit awards, the fair market value of the award is determined utilizing a Monte Carlo simulation model, which projects the value of the Company's stock under numerous scenarios and determines the value of the award based upon the present value of those projected outcomes.
The amount of stock-based compensation expense recognized is based on the portion of the awards that are ultimately expected to vest, excluding market and nonmarket performance award considerations discussed above. The Company estimates pre-vesting forfeitures at the time of grant by analyzing historical data and revises those estimates in subsequent periods if actual forfeitures differ from those estimates. The total expense recognized over the vesting period will only be for those awards that ultimately vest, excluding market and nonmarket performance award considerations. Note 10 “Stock-Based Compensation” contains additional information on the Company's stock-based compensation.
Foreign Currency Translation – The Company translates all assets and liabilities of its foreign subsidiaries, where the U.S. dollar is not the functional currency, at the period-end exchange rate and translates income and expenses at the average exchange rates in effect during the period. The net effect of this translation is recorded in the consolidated financial statements as Accumulated Other Comprehensive Income. Translation adjustments are not adjusted for income taxes as they relate to permanent investments in the Company's foreign subsidiaries.
Net foreign currency transaction gains and losses are included in Other (Income) Expense, Net and amounted to a loss of $0.1 million for 2011, a loss of $0.9 million for 2010 and a gain $0.7 million for 2009.
Defined Benefit Plans – The Company recognizes in its balance sheet as an asset or liability the overfunded or underfunded status of its defined benefit plans provided to its employees located in Mexico, Switzerland and France. This asset or liability is measured as the difference between the fair value of plan assets and the benefit obligation of those plans. For these plans, the benefit obligation is the projected benefit obligation, which is calculated based on actuarial computations of current and future benefits for employees. Actuarial gains or losses and prior service costs or credits that arise during the period, but are not included as components of net periodic benefit expense, are recognized as a component of Accumulated Other Comprehensive Income. Defined benefit expenses are charged to Cost of Sales, SG&A and RD&E expenses as applicable. Note 9 “Employee Benefit Plans” contains additional information on these costs.
Earnings (Loss) Per Share (“EPS”) – Basic EPS is calculated by dividing Net Income (Loss) by the weighted average number of shares outstanding during the period. Diluted EPS is calculated by adjusting the weighted average number of shares outstanding for potential common shares, which consist of stock options, unvested restricted stock and restricted stock units and contingently convertible instruments.
Holders of the Company's convertible subordinated notes may convert them into shares of the Company's common stock under certain circumstances – See Note 8 “Debt.” The Company includes the effect of the conversion of these convertible notes in the calculation of diluted EPS using the if-converted method or the treasury method for instruments that may be settled in cash at the Company's election and which the Company has the ability and intent to settle them in cash, as long as the effect is dilutive. For computation of EPS under conversion conditions, the number of diluted shares outstanding increases by the amount of shares that are potentially convertible during that period. Also, Net Income (Loss) is adjusted for the calculation to add back interest expense on the convertible notes as well as unamortized discount and deferred financing fee amortization recorded during the period. Note 15 “Earnings (Loss) Per Share” contains additional information on the computation of the Company's EPS.
Comprehensive Income (Loss) – The Company's comprehensive income (loss) as reported in the Consolidated Statements of Operations and Comprehensive Income (Loss) includes net income (loss), foreign currency translation adjustments, the net change in cash flow hedges, and defined benefit plan liability adjustments. The Consolidated Statements of Operations and Comprehensive Income (Loss) and Note 16 “Accumulated Other Comprehensive Income” contains additional information on the computation of the Company's comprehensive income (loss).
Use of Estimates – The preparation of financial statements in conformity with accounting principles generally accepted in the United States of America requires management to make estimates and assumptions that affect the reported amounts of assets and liabilities and disclosure of contingent assets and liabilities at the date of the financial statements and reported amounts of sales and expenses during the reporting period. Actual results could differ materially from those estimates.
Recently Issued Accounting Pronouncements – In the normal course of business, Management evaluates all new accounting pronouncements issued by the Financial Accounting Standards Board (“FASB”), Securities and Exchange Commission (“SEC”), Emerging Issues Task Force (“EITF”), American Institute of Certified Public Accountants (“AICPA”) or other authoritative accounting bodies to determine the potential impact they may have on the Company's Consolidated Financial Statements. Based upon this review, except as noted below, Management does not expect any of the recently issued accounting pronouncements, which have not already been adopted, to have a material impact on the Company's Consolidated Financial Statements.
In December 2011, the FASB issued Accounting Standards Update (“ASU”) No. 2011-11 “Balance Sheet (Topic 210): Disclosures about Offsetting Assets and Liabilities.” This ASU requires companies to provide information about trading in financial instruments and related derivatives in expanded disclosures, creates new disclosure requirements about the nature of an entity's rights of offset and related arrangements associated with its financial instruments and derivative instruments. The disclosure requirements are effective for annual reporting periods beginning on or after January 1, 2013, and interim periods therein, with retrospective application required. When adopted, this ASU will not have a material impact on the Company's Consolidated Financial Statements as it only changes the disclosures surrounding the Company's offsetting assets and liabilities.
In September 2011, the FASB issued ASU No. 2011-08 “Intangibles—Goodwill and Other (Topic 350): Testing Goodwill for Impairment.” This ASU modifies the impairment test for goodwill intangibles. Under the revised guidance, entities performing their annual goodwill impairment test have the option of performing a qualitative assessment before calculating the fair value of the reporting unit (i.e., step 1 of the goodwill impairment test). If entities determine, on the basis of this qualitative assessment, that the fair value of the reporting unit is more likely than not (i.e., a likelihood of more than 50 percent) less than the carrying amount, the two-step goodwill impairment test would be required. ASU No. 2011-08 is effective for the Company beginning in fiscal year 2012. Early adoption is permitted. The Company did not adopt ASU No. 2011-08 for its 2011 annual goodwill impairment test. When adopted, this ASU will not have a material impact on the Company's Consolidated Financial Statements as it only impacts the timing of when the Company is required to perform the two-step goodwill impairment test.
In June 2011, the FASB issued ASU No. 2011-05 “Comprehensive Income (Topic 220): Presentation of Comprehensive Income.” This ASU provides companies two choices for presenting net income and comprehensive income: in a single continuous statement, or in two separate, but consecutive, statements. Presenting comprehensive income in the statement of equity is no longer an option. ASU No. 2011-05 is effective for the Company beginning in fiscal year 2012. In December 2011, the FASB issued ASU No. 2011-12 “Comprehensive Income (Topic 220): Deferral of the Effective Date for Amendments to the Presentation of Reclassifications of Items Out of Accumulated Other Comprehensive Income in Accounting Standards Update No. 2011-05,” which delays the effective date of certain provisions of ASU No. 2011-05 related to the presentation of reclassification adjustments out of accumulated other comprehensive income. When adopted, ASU No. 2011-05 is not expected to have a material impact on the Company's Consolidated Financial Statements as it only changes the disclosures surrounding comprehensive income and as the Company already presents net income and comprehensive income in a single continuous statement.
In May 2011, the FASB issued ASU No. 2011-04 “Fair Value Measurement (Topic 820): Amendments to Achieve Common Fair Value Measurement and Disclosure Requirements in U.S. GAAP and IFRSs.” ASU No. 2011-04 establishes a global standard for applying fair value measurement. In addition to a few updates to the measurement guidance, ASU No. 2011-04 includes enhanced disclosure requirements. The most significant change for companies reporting under U.S. GAAP is an expansion of the disclosures required for “Level 3” measurements; that is, measurements based on unobservable inputs, such as a company's own data. This update is effective for the Company beginning in fiscal year 2012. The Company is currently assessing the impact of ASU No. 2011-04 on its Consolidated Financial Statements.
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2. ACQUISITIONS
Micro Power Electronics, Inc.
On December 15, 2011, Electrochem acquired all of the outstanding common and preferred stock of Micro Power Electronics, Inc. (“Micro Power”) headquartered in Beaverton, OR. Micro Power is a leading supplier of custom battery solutions, serving the portable medical, military and handheld automatic identification and data collection markets. Micro Power's commercial portfolio is highly complementary to the products and services offered by Electrochem.
This transaction was accounted for under the acquisition method of accounting. Accordingly, the results of Micro Power's operations were included in the consolidated financial statements from the date of acquisition. The aggregate purchase price consisted of the amount paid to Micro Power shareholders ($57.5 million), payments to Micro Power's creditors at closing ($6.6 million) and certain Micro Power transaction-related expenses ($7.6 million) that were paid or accrued at December 15, 2011. The Company's transaction costs associated with this acquisition ($0.6 million) were expensed as incurred through Other Operating Expenses, Net in the Consolidated Statement of Operations. The Company financed this acquisition with cash on hand and borrowed $45 million under its revolving credit facility. As of December 30, 2011, the Company has accrued $5.7 million of Micro Power transaction-related expenses, which were paid in the first quarter of 2012.
The cost of the acquisition was preliminarily allocated to the assets acquired and liabilities assumed from Micro Power based on their fair values as of the close of the acquisition, with the amount exceeding the fair value recorded as goodwill. As the values of certain assets and liabilities are preliminary in nature, they are subject to adjustment as additional information is obtained, including, but not limited to, the finalization of our intangible asset valuation, working capital adjustment as defined in the purchase agreement, pre-acquisition tax positions and branding analysis. The valuations will be finalized in 2012. When the valuations are finalized, any changes to the preliminary valuation of assets acquired or liabilities assumed may result in material adjustments to the fair value of the intangible assets acquired, as well as goodwill. The following table summarizes the preliminary allocation of the Micro Power purchase price to the assets acquired and liabilities assumed as of the acquisition date (in thousands):
Assets acquired | |||||
Current assets | $ | 25,683 | |||
Property, plant and equipment | 1,650 | ||||
Amortizing intangible assets | 29,276 | ||||
Goodwill | 31,478 | ||||
Other assets | 94 | ||||
Total assets acquired | 88,181 | ||||
Liabilities assumed | |||||
Current liabilities | 13,649 | ||||
Long-term liabilities | 2,834 | ||||
Total liabilities assumed | 16,483 | ||||
$ | 71,698 |
The preliminary fair values of the assets acquired were determined using one of three valuation approaches: market, income and cost. The selection of a particular method for a given asset depended on the reliability of available data and the nature of the asset, among other considerations.
The market approach, estimates the value for a subject asset based on available market pricing for comparable assets. The income approach, estimates the value for a subject asset based on the present value of cash flows projected to be generated by the asset. The projected cash flows were discounted at a required rate of return that reflects the relative risk of the asset and the time value of money. The projected cash flows for each asset considered multiple factors from the perspective of a marketplace participant including revenue projections from existing customers, attrition trends, product life-cycle assumptions, marginal tax rates and expected profit margins giving consideration to historical and expected margins. The cost approach estimates the value for a subject asset based on the cost to replace the asset and reflects the estimated reproduction or replacement cost for the asset, less an allowance for loss in value due to depreciation or obsolescence, with specific consideration given to economic obsolescence if indicated. These fair value measurement approaches are based on significant unobservable inputs, including management estimates and assumptions.
Current assets and liabilities - The fair value of current assets (excluding inventory) and current liabilities was assumed to approximate their carrying value as of the acquisition date due to the short-term nature of these assets and liabilities.
The fair value of in-process and finished goods inventory acquired was estimated by applying a version of the market approach called the comparable sales method. This approach estimates the fair value of the assets by calculating the potential revenue generated from selling the inventory and subtracting from it the costs related to the completion and sale of that inventory and a reasonable profit allowance. Based upon this methodology, the Company recorded the inventory acquired at fair value resulting in an increase in inventory of $0.7 million. During the fourth quarter of 2011, the Company expensed $0.2 million of this step-up value through Cost of Sales as the acquired inventory to which that step-up value was related was sold during that period. Raw materials inventory was valued at replacement cost.
Intangible assets - The purchase price was preliminarily allocated to specific intangible assets as follows (dollars in thousands):
Weighted | Weighted | |||||||||
Fair | Average | Estimated | Average | |||||||
Value | Amortization | Useful | Discount | |||||||
Amortizing Intangible Assets | Assigned | Period (Years) | Life (Years) | Rate | ||||||
Technology and patents | $ | 8,051 | 4 | 10 | 14% | |||||
Customer lists | 19,569 | 5 | 14 | 12% | ||||||
Noncompete agreement | 915 | 4 | 8 | 14% | ||||||
Trademarks and tradenames | 741 | 3 | 7 | 13% | ||||||
$ | 29,276 | 4 | 13 | 13% |
The weighted average amortization period is less than the estimated useful life, as the Company is using an accelerated amortization method, which approximates the distribution of cash flows used to fair value those intangible assets.
Technology and patents - Technology and patents consists of technical processes, patented and unpatented technology, manufacturing know-how and the understanding with respect to products or processes that have been developed by Micro Power and that will be leveraged in current and future products. The fair value of technology and patents acquired was determined utilizing the relief from royalty method, a form of the income approach, with royalty rates that ranged from 2% to 4%. The Company determined that the estimated useful life of the technology and patents is approximately 10 years. This life is based upon management's estimate of the product life cycle associated with technology and patents before they will be replaced by new technologies.
Customer lists – Customer lists represent the estimated fair value of both the contractual and non-contractual customer relationships Micro Power has as of the acquisition date. The primary customers of Micro Power include large OEM manufacturers such as Carefusion, Harris Communications, Philips Healthcare, Thales Communications, and Thoratec, some of which are also customers of Electrochem. These relationships were valued separately from goodwill at the amount which an independent third party would be willing to pay for these relationships. The fair value of customer lists was determined using the multi-period excess-earnings method, a form of the income approach. The Company determined that the estimated useful life of the existing customer lists is approximately 14 years. This life was based upon historical customer attrition as well as management's understanding of the industry and product life cycles.
Trademarks and tradenames – Trademarks and tradenames represent the estimated fair value of corporate and product names acquired from Micro Power, which will be utilized by the Company in the future. These tradenames were valued separately from goodwill at the amount which an independent third party would be willing to pay for use of these names. The fair value of the trademarks and tradenames was determined by utilizing the relief from royalty method, a form of the income approach, with a 0.5% royalty rate. The tradenames are inherently valuable as the Company believes they convey favorable perceptions about the products with which they are associated. This in turn generates consistent and increased demand for the products, which provides the Company with greater revenues, as well as greater production and operating efficiencies. Thus, the Company will realize larger profit margins than companies without the tradenames. The Company determined that the estimated useful life of the trademarks and tradenames is approximately 7 years.
Goodwill - The excess of the purchase price over the fair value of net tangible and intangible assets acquired of $31.5 million was allocated to goodwill. Various factors contributed to the establishment of goodwill, including: the value of Micro Power's highly trained assembled work force and management team; the expected revenue growth over time that is attributable to increased market penetration from future products and customers; and the incremental value to the Company's Electrochem business from expanding and diversifying its revenues. The goodwill acquired in connection with the Micro Power acquisition was allocated to the Electrochem business segment and is not deductible for tax purposes.
Pro Forma Results (Unaudited) - The following unaudited pro forma information presents the consolidated results of operations of the Company and Micro Power as if that acquisition had occurred as of the beginning of the 2010 fiscal year presented (in thousands, except per share amounts):
Year Ended | ||||||||
December 30, | December 31, | |||||||
2011 | 2010 | |||||||
Sales | $ | 631,561 | $ | 591,893 | ||||
Net income | 32,280 | 29,476 | ||||||
Earnings per share: | ||||||||
Basic | $ | 1.39 | $ | 1.28 | ||||
Diluted | $ | 1.37 | $ | 1.25 |
The unaudited pro forma information presents the combined operating results of Greatbatch and Micro Power, with the results prior to the acquisition date adjusted to include the pro forma impact of the amortization of acquired intangible assets based on the purchase price allocation, the elimination of non-recurring inventory step-up amortization recorded by Greatbatch ($0.7 million), the adjustment to interest income/expense reflecting the cash paid in connection with the acquisition, including acquisition–related expenses, at Greatbatch's weighted average interest income/expense rate, and the impact of income taxes on the pro forma adjustments utilizing the applicable statutory tax rate. The unaudited pro forma consolidated basic and diluted earnings per share are based on the consolidated basic and diluted weighted average shares of Greatbatch. For 2011, the Micro Power acquisition added approximately $2.5 million to revenue and was neutral to net income.
The unaudited pro forma results are presented for illustrative purposes only and do not reflect the realization of potential cost savings, and any related integration costs. Certain costs savings may result from the acquisition; however, there can be no assurance that these cost savings will be achieved. These pro forma results do not purport to be indicative of the results that would have been obtained, or to be a projection of results that may be obtained in the future.
Subsequent Event – On February 16, 2012, the Company purchased all of the outstanding common stock of NeuroNexus Technologies, Inc. (“NeuroNexus”) headquartered in Ann Arbor, MI. NeuroNexus is an active implantable medical device design firm specializing in developing and commercializing high-value neural interface technology, components and systems for neuroscience and clinical markets. NeuroNexus has an extensive intellectual property portfolio, core technologies and capabilities to support the development and manufacturing of innovative neural interface devices across a wide range of functions including neuromodulation, sensing, optical stimulation and targeted drug delivery applications. This transaction will be accounted for under the acquisition method of accounting. Accordingly, the results of NeuroNexus's operations will be included in the consolidated financial statements from the date of acquisition within the Greatbatch Medical segment. The aggregate purchase price, which includes the repayment of NeuroNexus debt at closing, was approximately $12 million and was funded with cash on hand.
|
3. SUPPLEMENTAL CASH FLOW INFORMATION
Year Ended | |||||||||||
December 30, | December 31, | January 1, | |||||||||
(in thousands) | 2011 | 2010 | 2010 | ||||||||
Noncash investing and financing activities: | |||||||||||
Unrealized (loss) gain on cash flow hedges, net | $ | (271) | $ | 1,027 | $ | (200) | |||||
Common stock contributed to 401(k) Plan | - | - | 4,015 | ||||||||
Property, plant and equipment purchases | |||||||||||
included in accounts payable | 4,455 | 2,614 | 1,259 | ||||||||
Unsettled purchase of treasury stock | - | - | 632 | ||||||||
Cash paid during the year for: | |||||||||||
Interest | 6,148 | 8,498 | 9,234 | ||||||||
Income taxes | 5,259 | 3,826 | 4,473 | ||||||||
Acquisition of noncash assets | 87,766 | 350 | - | ||||||||
Liabilities assumed | 16,483 | - | - |
|
4. INVENTORIES
Inventories are comprised of the following (in thousands): | |||||||
At | |||||||
December 30, | December 31, | ||||||
2011 | 2010 | ||||||
Raw materials | $ | 49,773 | $ | 45,974 | |||
Work-in-process | 36,603 | 34,659 | |||||
Finished goods | 23,537 | 20,807 | |||||
Total | $ | 109,913 | $ | 101,440 |
|
5. PROPERTY, PLANT AND EQUIPMENT
Property, plant and equipment are comprised of the following (in thousands): | |||||||
At | |||||||
December 30, | December 31, | ||||||
2011 | 2010 | ||||||
Manufacturing machinery and equipment | $ | 149,136 | $ | 135,108 | |||
Buildings and building improvements | 75,229 | 71,160 | |||||
Information technology hardware and software | 33,881 | 32,700 | |||||
Leasehold improvements | 17,426 | 17,282 | |||||
Furniture and fixtures | 11,282 | 10,475 | |||||
Land and land improvements | 11,075 | 10,332 | |||||
Construction work in process | 13,302 | 11,639 | |||||
Other | 993 | 808 | |||||
312,324 | 289,504 | ||||||
Accumulated depreciation | (166,518) | (143,124) | |||||
Total | $ | 145,806 | $ | 146,380 |
Depreciation expense for property, plant and equipment was as follows (in thousands): | |||||||||||
Year Ended | |||||||||||
December 30, | December 31, | January 1, | |||||||||
2011 | 2010 | 2010 | |||||||||
Depreciation expense | $ | 25,672 | $ | 26,104 | $ | 27,059 |
Construction work in process at December 30, 2011 primarily relates to the construction of the Company's Orthopaedic manufacturing facility in Allen County, IN. See Note 12 for a description of the Company's significant capital investment projects.
|
6. INTANGIBLE ASSETS
Amortizing intangible assets are comprised of the following (in thousands): | |||||||||||||
At | December 30, 2011 | Gross Carrying Amount | Accumulated Amortization | Foreign Currency Translation | Net Carrying Amount | ||||||||
Purchased technology and patents | $ | 97,324 | $ | (54,054) | $ | 842 | $ | 44,112 | |||||
Customer lists | 66,388 | (14,009) | 1,807 | 54,186 | |||||||||
Other | 5,174 | (4,019) | 805 | 1,960 | |||||||||
Total amortizing intangible assets | $ | 168,886 | $ | (72,082) | $ | 3,454 | $ | 100,258 | |||||
At | December 31, 2010 | ||||||||||||
Purchased technology and patents | $ | 83,023 | $ | (48,187) | $ | 1,212 | $ | 36,048 | |||||
Customer lists | 46,818 | (10,577) | 2,119 | 38,360 | |||||||||
Other | 3,519 | (2,862) | 49 | 706 | |||||||||
Total amortizing intangible assets | $ | 133,360 | $ | (61,626) | $ | 3,380 | $ | 75,114 |
Aggregate intangible asset amortization expense is comprised of the following (in thousands): | |||||||||||
Year Ended | |||||||||||
December 30, | December 31, | January 1, | |||||||||
2011 | 2010 | 2010 | |||||||||
Cost of sales | $ | 6,163 | $ | 5,897 | $ | 6,331 | |||||
Selling, general and administrative expenses | 3,926 | 3,765 | 3,729 | ||||||||
Research, development and engineering costs | 367 | - | - | ||||||||
Total intangible asset amortization expense | $ | 10,456 | $ | 9,662 | $ | 10,060 |
Estimated future intangible asset amortization expense based upon the current carrying value is as follows (in thousands): | |||
Estimated | |||
Amortization | |||
Expense | |||
2012 | $ | 14,225 | |
2013 | 13,384 | ||
2014 | 13,533 | ||
2015 | 12,334 | ||
2016 | 10,123 | ||
Thereafter | 36,659 | ||
Total estimated amortization expense | $ | 100,258 |
During 2011, the Company made various asset purchases of technology and patents totaling $6.3 million, which is being amortized over a weighted average period of approximately 11 years. In connection with these purchases, the Company recorded a $3.0 million contingent liability, which will only be paid if certain sales targets for products that utilize that technology are achieved. This contingent liability is currently classified in Other Long-Term Liabilities.
As a result of the successful rebranding of the Company, during the fourth quarter of 2009, the Company wrote-down its non-Greatbatch trademarks and tradenames by $15.9 million. This charge was recorded based upon the Company's decision to discontinue use of the associated tradenames and determination that there were no market participants willing to purchase the previously acquired tradenames. In addition to the above, the Company incurred expense of $0.7 million in 2009 related to its rebranding initiative, which includes additional advertising costs, and is included in SG&A. As of December 30, 2011 and December 31, 2010, the Company had a $20.3 million indefinite-lived intangible asset recorded relating to its Greatbatch tradename.
The change in goodwill during 2011 is as follows (in thousands): | ||||||||||
Greatbatch Medical | Electrochem | Total | ||||||||
At | December 31, 2010 | $ | 297,508 | $ | 9,943 | $ | 307,451 | |||
Goodwill acquired | - | 31,478 | 31,478 | |||||||
Foreign currency translation | (276) | 0 | (276) | |||||||
At | December 30, 2011 | $ | 297,232 | $ | 41,421 | $ | 338,653 |
As of December 30, 2011, no accumulated impairment loss has been recognized for the goodwill allocated to the Company's Greatbatch Medical or Electrochem segments.
|
7. ACCRUED EXPENSES
Accrued expenses are comprised of the following (in thousands): | |||||||
As of | |||||||
December 30, | December 31, | ||||||
2011 | 2010 | ||||||
Salaries and benefits | $ | 13,618 | $ | 13,104 | |||
Profit sharing and bonuses | 19,971 | 8,443 | |||||
Warranty | 2,013 | 2,313 | |||||
Micro Power purchase price payable | 5,690 | - | |||||
Other | 11,247 | 8,224 | |||||
Total | $ | 52,539 | $ | 32,084 |
|
8. DEBT
Long-term debt is comprised of the following (in thousands): | |||||||
At | |||||||
December 30, | December 31, | ||||||
2011 | 2010 | ||||||
Revolving line of credit | $ | 55,000 | $ | 50,000 | |||
2.25% convertible subordinated notes, due 2013 | 197,782 | 197,782 | |||||
Unamortized discount | (16,832) | (27,153) | |||||
Total long-term debt | $ | 235,950 | $ | 220,629 |
Revolving Line of Credit – On June 24, 2011, the Company amended and extended its revolving credit facility (the “2011 Credit Facility”) to replace its then existing credit facility, which had an expiration date of May 22, 2012. The 2011 Credit Facility provides a $400 million secured revolving credit facility, which can be increased to $600 million upon the Company's request and approval by a majority of the lenders. The 2011 Credit Facility also contains a $15 million letter of credit subfacility and a $15 million swingline subfacility. The 2011 Credit Facility has a maturity date of June 24, 2016; provided, however, if CSN (defined below) is not repaid in full, modified or refinanced before March 1, 2013, the maturity date of the 2011 Credit Facility will be March 1, 2013.
The 2011 Credit Facility is secured by the Company's non-realty assets including cash, accounts receivable and inventories. Interest rates under the 2011 Credit Facility are, at the Company's option either at: (i) the higher of (a) the prime rate and (b) the federal funds rate plus 0.5%, plus the applicable margin, which ranges between 0.0% and 1.0%, based on the Company's total leverage ratio or (ii) the applicable LIBOR rate plus the applicable margin, which ranges between 1.5% and 3.0%, based on the Company's total leverage ratio. Loans under the swingline subfacility will bear interest at the higher of (a) the prime rate and (b) the federal funds rate plus 0.5%, plus the applicable margin, which ranges between 0.0% and 1.0%, based on the Company's total leverage ratio. The Company is also required to pay a commitment fee which, varies between 0.175% and 0.25% depending on the Company's total leverage ratio.
The 2011 Credit Facility contains limitations on the incurrence of indebtedness, liens and licensing of intellectual property, investments and certain payments. The 2011 Credit Facility permits the Company to engage in the following activities up to an aggregate amount of $250 million: 1) engage in permitted acquisitions in the aggregate not to exceed $250 million; 2) make other investments in the aggregate not to exceed $60 million; 3) make stock repurchases not to exceed $60 million in the aggregate; and 4) retire up to $198 million of Greatbatch, Inc.'s CSN. At any time that the total leverage ratio of the Company for the two most recently ended fiscal quarters is less than 2.75 to 1.0, the Company may make an election to reset each of the amounts specified in clauses (1) through (4) above. Additionally, these limitations can be waived upon the Company's request and approval of a majority of the lenders. As of December 30, 2011, the Company had available to it the full amount of the above limits except for the permitted acquisitions limit which is $178 million due to the Micro Power acquisition.
The 2011 Credit Facility requires the Company to maintain a rolling four quarter ratio of adjusted EBITDA to interest expense of at least 3.0 to 1.0, and a total leverage ratio of not greater than 4.5 to 1.0 through December 30, 2011 and not greater than 4.0 to 1.0 from December 31, 2011 and thereafter. The calculation of adjusted EBITDA and total leverage ratio excludes non-cash charges, extraordinary, unusual, or non-recurring expenses or losses, non-cash stock-based compensation, and non-recurring expenses or charges incurred in connection with permitted acquisitions. As of December 30, 2011, the Company was in compliance with all covenants.
The 2011 Credit Facility contains customary events of default. Upon the occurrence and during the continuance of an event of default, a majority of the lenders may declare the outstanding advances and all other obligations under the 2011 Credit Facility immediately due and payable.
The weighted average interest rate on borrowings under the 2011 Credit Facility as of December 30, 2011, was 2.25%. As of December 30, 2011, the Company had $345 million of borrowing capacity available under the 2011 Credit Facility. This amount may vary from period to period based upon the debt levels of the Company as well as the level of EBITDA, which impacts the covenant calculations as described above.
Interest Rate Swaps – In 2008, the Company entered into three receive floating-pay fixed interest rate swaps indexed to the six-month LIBOR rate, in order to hedge against potential changes in cash flows on the Company's outstanding debt, which was also indexed to the six-month LIBOR rate. As of December 30, 2011, none of these interest rate swaps remain outstanding. The receive variable leg of the interest rate swaps and the variable rate paid on the debt had the same rate of interest, excluding the credit spread, and reset and paid interest on the same dates. The Company accounted for these interest rate swaps as cash flow hedges. No portion of the change in fair value of the interest rate swaps during the 2011, 2010 or 2009 periods was considered ineffective. The amount recorded as Interest Expense related to the interest rate swaps was $0.4 million, $1.7 million, and $1.4 million during 2011, 2010 and 2009, respectively.
Convertible Subordinated Notes – In March 2007, the Company completed a private placement of $197.8 million of 2.25% convertible subordinated notes, due June 15, 2013 (“CSN”). CSN bear interest at 2.25% per annum, payable semi-annually, are due on June 15, 2013, and were issued at a 5% discount. The holders may convert the notes into shares of the Company's common stock at a conversion price of $34.70 per share, which is equivalent to a conversion ratio of 28.8219 shares per $1,000 of principal. The conversion price and the conversion ratio will adjust automatically upon certain changes to the Company's capitalization. The fair value of CSN as of December 30, 2011 was approximately $194 million and is based on recent sales prices.
The effective interest rate of CSN, which takes into consideration the amortization of the discount and deferred fees related to the issuance of these notes, is approximately 8.5%. The discount on CSN is being amortized to the maturity date of the convertible notes utilizing the effective interest method. As of December 30, 2011, the carrying amount of the discount related to the CSN conversion option was $14.3 million. As of December 30, 2011, the if-converted value of the CSN notes does not exceed their principal amount as the Company's closing stock price of $22.10 per share did not exceed the conversion price of $34.70 per share, thus none of these shares were included in the weighted average share calculation of diluted earnings per share (“EPS”).
The contractual interest and discount amortization for CSN were as follows (in thousands): | |||||||||
Year Ended | |||||||||
December 30, | December 31, | January 1, | |||||||
2011 | 2010 | 2010 | |||||||
Contractual interest | $ | 4,450 | $ | 4,450 | $ | 4,450 | |||
Discount amortization | 10,320 | 9,657 | 9,038 |
The notes are convertible at the option of the holders at such time as: (i) the closing price of the Company's common stock exceeds 150% of the conversion price of the notes for 20 out of 30 consecutive trading days; (ii) the trading price per $1,000 of principal is less than 98% of the product of the closing sale price of common stock for each day during any five consecutive trading day period and the conversion rate per $1,000 of principal; (iii) the notes have been called for redemption; (iv) the Company distributes to all holders of common stock rights or warrants entitling them to purchase additional shares of common stock at less than the average closing price of common stock for the ten trading days immediately preceding the announcement of the distribution; (v) the Company distributes to all holders of common stock any form of dividend which has a per share value exceeding 5% of the price of the common stock on the day prior to such date of distribution; (vi) the Company effects a consolidation, merger, share exchange or sale of assets pursuant to which its common stock is converted to cash or other property; (vii) the period beginning 60 days prior to but excluding June 15, 2013; and (viii) certain fundamental changes, as defined in the indenture governing the notes, occur or are approved by the Board of Directors.
Conversions in connection with corporate transactions that constitute a fundamental change require the Company to pay a premium make-whole amount, based upon a predetermined table as set forth in the indenture agreement, whereby the conversion ratio on the notes may be increased by up to 7.0 shares per $1,000 of principal. The premium make-whole amount will be paid in shares of common stock upon any such conversion, subject to the net share settlement feature of the notes described below.
CSN contains a net share settlement feature that requires the Company to pay cash for each $1,000 of principal to be converted. Any amounts in excess of $1,000 will be settled in shares of the Company's common stock, or at the Company's option, cash. The Company has a one-time irrevocable election to pay the holders in shares of its common stock, which it currently does not plan to exercise.
CSN are redeemable by the Company at any time on or after June 20, 2012, or at the option of a holder upon the occurrence of certain fundamental changes, as defined in the indenture, affecting the Company. The notes are subordinated in right of payment to all of our senior indebtedness and effectively subordinated to all debts and other liabilities of the Company's subsidiaries.
Deferred Financing Fees - The change in deferred financing fees is as follows (in thousands): | |||||
At | January 1, 2010 | $ | 3,028 | ||
Amortization during the period | (1,023) | ||||
At | December 31, 2010 | 2,005 | |||
Financing costs deferred | 2,213 | ||||
Write-off during the period | (51) | ||||
Amortization during the period | (1,018) | ||||
At | December 30, 2011 | $ | 3,149 |
|
9. EMPLOYEE BENEFIT PLANS
Savings Plan – The Company sponsors a defined contribution 401(k) plan, which covers substantially all of its U.S. based employees. The plan provides for the deferral of employee compensation under Section 401(k) and a discretionary Company match. In 2011, 2010, and 2009, this match was $0.35 per dollar of participant deferral, up to 6% of the total compensation for each participant. Net costs related to this defined contribution plan were $1.6 million in 2011 and $1.5 million in 2010, and 2009.
In addition to the above, under the terms of the 401(k) plan document there is an annual discretionary defined contribution of up to five percent of each employee's eligible compensation. This amount is contributed to the 401(k) plan in the form of Company stock. Compensation cost recognized related to the defined contribution was $5.1 million in 2011. No discretionary contribution was made for fiscal years 2010, or 2009 as the Company did not achieve the applicable performance targets for those years. As of December 30, 2011, the 401(k) Plan held 543,320 shares of Company stock.
Education Assistance Program – The Company reimburses tuition, textbooks and laboratory fees for college or other job related programs for all of its U.S. based employees. The Company also reimburses college tuition for the dependent children of certain full-time U.S. based employees, which vests on a straight-line basis over ten years, up to the applicable local state university tuition rate. For certain employees and executives, the dependent children benefit is not limited. Minimum academic achievement is required in order to receive reimbursement under both programs. Aggregate expenses under the programs were $1.5 million, $1.3 million and $1.5 million in 2011, 2010 and 2009, respectively. The dependent tuition reimbursement program was frozen on December 14, 2011 and is now limited to those U.S. employees who were employed by the Company as of that date.
Defined Benefit Plans – The Company is required to provide its employees located in Switzerland, Mexico, and France certain statutorily mandated defined benefits. Under these plans, benefits accrue to employees based upon years of service, position, age and compensation. The defined benefit pension plan provided to the Company's employees located in Switzerland is a funded contributory plan while the defined benefit plans provided to the Company's employees located in Mexico and France are unfunded and noncontributory. The Company expects 2012 contributions to these defined benefit plans to be similar to those made in 2011 and 2010.
Information relating to the funding position of the Company's defined benefit plans as of the plans measurement date of December 30, 2011 and December 31, 2010 were as follows (in thousands):
Year Ended | |||||||
December 30, | December 31, | ||||||
2011 | 2010 | ||||||
Change in projected benefit obligation: | |||||||
Projected benefit obligation at beginning of year | $ | 15,961 | $ | 14,294 | |||
Service cost | 1,127 | 724 | |||||
Interest cost | 483 | 383 | |||||
Prior service cost | 125 | 143 | |||||
Plan participants' contribution | 999 | 863 | |||||
Actuarial loss | 393 | 257 | |||||
Benefits paid | (1,396) | (590) | |||||
Settlements/curtailments | 0 | (1,524) | |||||
Plan amendment | (582) | 0 | |||||
Foreign currency translation | (57) | 1,411 | |||||
Projected benefit obligation at end of year | 17,053 | 15,961 | |||||
Change in fair value of plan assets: | |||||||
Fair value of plan assets at beginning of year | 11,314 | 10,320 | |||||
Employer contributions | 1,041 | 913 | |||||
Plan participants' contributions | 999 | 863 | |||||
Actual loss on plan assets | (443) | (278) | |||||
Benefits paid | (1,380) | (559) | |||||
Settlements | 0 | (1,050) | |||||
Foreign currency translation | (47) | 1,105 | |||||
Fair value of plan assets at end of year | 11,484 | 11,314 | |||||
Projected benefit obligation in excess of plan | |||||||
assets at end of year | $ | 5,569 | $ | 4,647 | |||
Pension liability classified as other current liabilities | $ | 21 | $ | 6 | |||
Pension liability classified as long-term liabilities | $ | 5,548 | $ | 4,641 | |||
Accumulated benefit obligation at end of year | $ | 14,962 | $ | 14,218 |
Amounts recognized in Accumulated Other Comprehensive Income are as follows (in thousands): | ||||||||
Year Ended | ||||||||
December 30, | December 31, | |||||||
2011 | 2010 | |||||||
Net loss occurring during the year | $ | 1,306 | $ | 916 | ||||
Amortization of losses | (59) | (586) | ||||||
Prior service cost | (459) | 143 | ||||||
Amortization of prior service cost | (137) | (4) | ||||||
Foreign currency translation | (5) | 90 | ||||||
Pre-tax adjustment | 646 | 559 | ||||||
Taxes | (80) | 42 | ||||||
Net loss | $ | 566 | $ | 601 |
The amortization of amounts in Accumulated Other Comprehensive Income expected to be recognized as components of net periodic benefit expense during 2012 are as follows (in thousands):
Amortization of net prior service credit | $ | (41) | |
Amortization of net loss | 165 |
Net pension cost is comprised of the following (in thousands): | ||||||
Year Ended | ||||||
December 30, | December 31, | |||||
2011 | 2010 | |||||
Service cost | $ | 1,127 | $ | 724 | ||
Interest cost | 483 | 383 | ||||
Expected return on assets | (470) | (381) | ||||
Settlements | 0 | 87 | ||||
Recognized net actuarial loss | 200 | 30 | ||||
Net pension cost | $ | 1,340 | $ | 843 | ||
The weighted-average rates used in the actuarial valuations were as follows: | ||||||||||
Projected Benefit Obligation | Net Pension Cost | |||||||||
December 30, | December 31, | |||||||||
2011 | 2010 | 2011 | 2010 | 2009 | ||||||
Discount rate | 2.5% | 2.9% | 2.9% | 3.0% | 3.0% | |||||
Salary growth | 2.3% | 2.5% | 2.5% | 2.5% | 2.5% | |||||
Expected rate of return on assets | 3.5% | 3.8% | 3.8% | 4.0% | 4.0% | |||||
Long-term inflation rate | 1.3% | 1.5% | 1.5% | 1.5% | 1.5% |
The discount rate used is based on the yields of Switzerland AA bonds with a duration matching the duration of the liabilities plus approximately 50 basis points to reflect the risk of investing in corporate bonds. The expected rate of return on plan assets reflects long-term earnings expectations on existing plan assets and those contributions expected to be received during the current plan year. In estimating that rate, appropriate consideration was given to historical returns earned by plan assets in the fund and the rates of return expected to be available for reinvestment. Rates of return were adjusted to reflect current capital market assumptions and changes in investment allocations. Equity securities and fixed income securities were assumed to earn a return in the range of 6% to 8% and 2.25%, respectively. When these overall return expectations are applied to the pension plan's target allocation, the expected rate of return is determined to be 3.5%.
Plan assets were comprised of the following (in thousands): | ||||||||||||
Fair Value Measurements Using | ||||||||||||
December 30, | Quoted Prices in Active Markets for Identical Assets | Significant Other Observable Inputs | Significant Unobservable Inputs | |||||||||
2011 | (Level 1) | (Level 2) | (Level 3) | |||||||||
Cash | $ | 179 | $ | 179 | $ | - | $ | - | ||||
Equity securities: | ||||||||||||
U.S. companies | 1,019 | 1,019 | - | - | ||||||||
International companies | 2,155 | 2,155 | - | - | ||||||||
Emerging markets | 415 | 415 | - | - | ||||||||
Fixed income: | ||||||||||||
Government & government agencies | 4,057 | 4,057 | - | - | ||||||||
Corporate | 1,860 | 1,860 | - | - | ||||||||
Real-estate | 1,064 | - | 1,064 | - | ||||||||
Other | 735 | 735 | - | - | ||||||||
Total | $ | 11,484 | $ | 10,420 | $ | 1,064 | $ | - |
Fair Value Measurements Using | ||||||||||||
December 31, | Quoted Prices in Active Markets for Identical Assets | Significant Other Observable Inputs | Significant Unobservable Inputs | |||||||||
2010 | (Level 1) | (Level 2) | (Level 3) | |||||||||
Cash | $ | 84 | $ | 84 | $ | - | $ | - | ||||
Equity securities: | ||||||||||||
U.S. companies | 969 | 969 | - | - | ||||||||
International companies | 2,310 | 2,310 | - | - | ||||||||
Emerging markets | 464 | 464 | - | - | ||||||||
Fixed income: | ||||||||||||
Government & government agencies | 4,336 | 4,336 | - | - | ||||||||
Corporate | 1,034 | 1,034 | - | - | ||||||||
Real-estate | 1,081 | - | 1,081 | - | ||||||||
Other | 1,036 | 1,036 | - | - | ||||||||
Total | $ | 11,314 | $ | 10,233 | $ | 1,081 | $ | - |
The fair value of Level 1 plan assets are obtained by reference to the last quoted price of the identical security on the market which it trades. The fair value of Level 2 plan assets are obtained from quoted market prices in inactive markets or valuation models with observable market data inputs to estimate fair value. These observable market data inputs include benchmark yields, reported trades, broker/dealer quotes, issuer spreads, benchmark securities, bids, offers and reference data.
The weighted average target and actual pension fund asset allocation as of the valuation date was as follows: | ||||||||
2011 | ||||||||
Asset Category: | Target | Actual | ||||||
Fixed income | 54.0% | 52.0% | ||||||
Equity | 31.0% | 31.0% | ||||||
Real-estate | 10.0% | 9.0% | ||||||
Cash | 0.0% | 2.0% | ||||||
Other | 5.0% | 6.0% | ||||||
100.0% | 100.0% |
The target allocation is consistent with the Company's goal of diversifying plan assets in order to preserve capital while achieving investment results that will contribute to the proper funding of benefit obligations and cash flow requirements.
Estimated benefit payments over the next ten years are as follows (in thousands): | ||||||||
2012 | $ | 773 | ||||||
2013 | 992 | |||||||
2014 | 989 | |||||||
2015 | 1,039 | |||||||
2016 | 1,035 | |||||||
2017-2021 | 6,637 |
|
10. STOCK-BASED COMPENSATION
The components and classification of stock-based compensation expense were as follows (in thousands): | ||||||||||
Year Ended | ||||||||||
December 30, | December 31, | January 1, | ||||||||
2011 | 2010 | 2010 | ||||||||
Stock options | $ | 2,511 | $ | 2,617 | $ | 2,631 | ||||
Restricted stock and units | 4,526 | 4,267 | 2,573 | |||||||
401(k) stock contribution | 5,045 | - | - | |||||||
Total stock-based compensation expense | $ | 12,082 | $ | 6,884 | $ | 5,204 | ||||
Cost of sales | $ | 4,184 | $ | 509 | $ | 398 | ||||
Selling, general and administrative | 6,630 | 5,982 | 4,375 | |||||||
Research, development and engineering | 1,268 | 393 | 431 | |||||||
Total stock-based compensation expense | $ | 12,082 | $ | 6,884 | $ | 5,204 |
During 2010 and 2009, the Company reversed approximately $0.3 million and $2.6 million, respectively, of performance stock-based compensation expense as it was no longer probable that the performance metrics would be achieved on those awards. During 2010, the Company recorded $0.7 million of stock-based compensation expense related to the accelerated vesting of equity awards issued to the Company's former Senior Vice President - Orthopaedics, who died during the year.
Summary of Plans
The Company's 1998 Stock Option Plan, 2002 Restricted Stock Plan and Non-Employee Directors Plan have been frozen to any new award issuances. Stock option and restricted stock awards remain outstanding under these plans.
The Company's 2005 Stock Incentive Plan (“2005 Plan”), as amended, authorizes the issuance of up to 2,450,000 shares of equity incentive awards including nonqualified and incentive stock options, restricted stock, restricted stock units, stock bonuses and stock appreciation rights subject to the terms of the 2005 Plan. The 2005 Plan limits the amount of restricted stock, restricted stock units and stock bonuses that may be awarded in the aggregate to 850,000 shares of the 2,450,000 shares authorized by the 2005 Plan.
The Company's 2009 Stock Incentive Plan (“2009 Plan”) authorizes the issuance of up to 1,350,000 shares of equity incentive awards including nonqualified and incentive stock options, restricted stock, restricted stock units, stock bonuses and stock appreciation rights subject to the terms of the 2009 Plan. The 2009 Plan limits the amount of restricted stock, restricted stock units and stock bonuses that may be awarded in the aggregate to 200,000 shares of the 1,350,000 shares authorized.
In 2011, stockholders of the Company approved the Greatbatch, Inc. 2011 Stock Incentive Plan (the “2011 Plan”). The 2011 Plan authorizes the issuance of up to 1,000,000 shares of equity incentive awards including nonqualified and incentive stock options, restricted stock, restricted stock units, stock bonuses and stock appreciation rights, subject to the terms of the 2011 Plan. The 2011 Plan does not limit the amount of restricted stock, restricted stock units or stock bonuses that may be awarded.
As of December 30, 2011, there were 894,936, 626,402 and 313,020 shares available for future grants under the 2011 Plan, 2009 Plan and 2005 Plan, respectively. Due to plan sub-limits, of the shares available for grant, only 731 shares and 18,426 shares may be awarded under the 2009 Plan and the 2005 Plan, respectively, in the form of restricted stock, restricted stock units or stock bonuses.
Stock Options
Stock options granted generally vest over a three or four year period, expire 10 years from the date of grant, and are granted at exercise prices equal to or greater than the fair value of the Company's common stock on the date of grant. Performance-based stock options only vest if certain performance metrics are achieved. The performance metrics generally cover a three-year performance period beginning in the year of grant and include the achievement of revenue, adjusted operating earnings and adjusted operating cash flow targets. In 2010, the Company began issuing all performance stock-based awards in the form of restricted stock units.
The Company utilizes the Black-Scholes option pricing model to determine the fair value of stock options. Management is required to make certain assumptions with respect to selected model inputs. Expected volatility is based on the historical volatility of the Company's stock over the most recent period commensurate with the estimated expected life of the stock options. The expected life of stock options, which represents the period of time that the stock options are expected to be outstanding, is based on historical data. The expected dividend yield is based on the Company's history and expectation of future dividend payouts. The risk-free interest rate is based on the U.S. Treasury yield curve in effect at the time of grant for a period commensurate with the estimated expected life. If factors change and result in different assumptions, the stock option expense that the Company records for future grants may differ significantly from what the Company recorded in the current period. Stock-based compensation expense is only recorded for those awards that are expected to vest. Pre-vesting forfeiture estimates for determining appropriate stock-based compensation expense are estimated at the time of grant based on historical experience. Revisions are made to those estimates in subsequent periods if actual forfeitures differ from estimated forfeitures. For retirement eligible employees, whose awards immediately vest, a 0% forfeiture rate is used.
The weighted-average fair value and assumptions used are as follows: | |||||||||
Year Ended | |||||||||
December 30, | December 31, | January 1, | |||||||
2011 | 2010 | 2010 | |||||||
Weighted average grant date fair value | $ | 9.37 | $ | 8.24 | $ | 8.63 | |||
Risk-free interest rate | 2.02% | 2.62% | 2.03% | ||||||
Expected volatility | 40% | 40% | 39% | ||||||
Expected life (in years) | 5.3 | 5.4 | 5.6 | ||||||
Expected dividend yield | 0% | 0% | 0% | ||||||
Annual prevesting forfeiture rate | 9% | 9% | 9% |
The following table summarizes time-vested stock option activity: | |||||||||||||||
Number of Time-Vested Stock Options | Weighted Average Exercise Price | Weighted Average Remaining Contractual Life (In Years) | Aggregate Intrinsic Value (In Millions) | ||||||||||||
Outstanding at January 2, 2009 | 1,498,294 | $ | 24.28 | ||||||||||||
Granted | 243,920 | 26.53 | |||||||||||||
Exercised | (13,736) | 15.45 | |||||||||||||
Forfeited or expired | (366,355) | 27.27 | |||||||||||||
Outstanding at January 1, 2010 | 1,362,123 | 23.94 | |||||||||||||
Granted | 243,155 | 20.57 | |||||||||||||
Exercised | (34,196) | 19.26 | |||||||||||||
Forfeited or expired | (107,526) | 24.43 | |||||||||||||
Outstanding at December 31, 2010 | 1,463,556 | 23.46 | |||||||||||||
Granted | 306,449 | 23.98 | |||||||||||||
Exercised | (84,237) | 21.41 | |||||||||||||
Forfeited or expired | (126,997) | 26.47 | |||||||||||||
Outstanding at December 30, 2011 | 1,558,771 | $ | 23.42 | 6.1 | $ | 1.5 | |||||||||
Expected to vest at December 30, 2011 | 1,529,168 | $ | 23.42 | 6.1 | $ | 1.5 | |||||||||
Exercisable at December 30, 2011 | 1,236,993 | $ | 23.51 | 5.6 | $ | 1.3 |
The following table summarizes performance-vested stock option activity: | |||||||||||||||
Number of Performance-Vested Stock Options | Weighted Average Exercise Price | Weighted Average Remaining Contractual Life (In Years) | Aggregate Intrinsic Value (In Millions) | ||||||||||||
Outstanding at January 2, 2009 | 798,564 | $ | 23.62 | ||||||||||||
Granted | 310,407 | 26.53 | |||||||||||||
Forfeited or expired | (106,987) | 24.00 | |||||||||||||
Outstanding at January 1, 2010 | 1,001,984 | 24.48 | |||||||||||||
Forfeited or expired | (257,461) | 26.81 | |||||||||||||
Outstanding at December 31, 2010 | 744,523 | 23.68 | |||||||||||||
Exercised | (26,478) | 22.53 | |||||||||||||
Forfeited or expired | (239,681) | 22.29 | |||||||||||||
Outstanding at December 30, 2011 | 478,364 | $ | 24.44 | 5.9 | $ | 0.0 | |||||||||
Expected to Vest at December 30, 2011 | 308,299 | $ | 23.29 | 5.3 | $ | 0.0 | |||||||||
Exercisable at December 30, 2011 | 251,610 | $ | 22.56 | 5.0 | $ | 0.0 |
Intrinsic value is calculated for in-the-money options (exercise price less than market price) outstanding and/or exercisable as the difference between the market price of the Company's common shares as of December 30, 2011 ($22.10) and the weighted average exercise price of the underlying stock options, multiplied by the number of options outstanding and/or exercisable. As of December 30, 2011, $2.7 million of unrecognized compensation cost related to non-vested stock options is expected to be recognized over a weighted-average period of approximately 2 years. Shares are distributed from the Company's authorized but unissued reserve upon the exercise of stock options or treasury stock if available. The Company does not intend to purchase treasury shares to fund the future exercises of stock options.
Proceeds from the exercise of stock options are credited to common stock at par value and the excess is credited to additional paid-in capital. A portion of the options outstanding qualify as incentive stock options (“ISO”) for income tax purposes. As such, a tax benefit is not recorded at the time the compensation cost related to the stock options is recorded for book purposes due to the fact that an ISO does not ordinarily result in a tax benefit unless there is a disqualifying disposition. Stock option grants of non-qualified stock options result in the creation of a deferred tax asset, which is a temporary difference, until the time that the option is exercised.
The following table provides certain information relating to the exercise of stock options (in thousands):
Year Ended | |||||||||
December 30, | December 31, | January 1, | |||||||
2011 | 2010 | 2010 | |||||||
Intrinsic value | $ | 501 | $ | 112 | $ | 80 | |||
Cash received | 2,401 | 659 | 212 | ||||||
Tax (expense) benefit realized | (146) | (41) | 24 |
Restricted Stock and Restricted Stock Units
Time-vested restricted stock and restricted stock unit awards granted typically vest 50% on the second fiscal year-end from the date of the award and 25% on the third and fourth fiscal year-ends from the date of the award. The fair value of time-based as well as nonmarket-based performance restricted stock and restricted stock unit awards is equal to the fair value of the Company's stock on the date of grant. The following table summarizes time-vested restricted stock and unit activity:
Time-Vested Activity | Weighted Average Fair Value | ||||||||
Nonvested at | January 2, 2009 | 183,765 | $ | 22.84 | |||||
Granted | 100,358 | 26.17 | |||||||
Vested | (104,412) | 23.79 | |||||||
Forfeited | (18,713) | 23.49 | |||||||
Nonvested at | January 1, 2010 | 160,998 | 24.22 | ||||||
Granted | 124,747 | 21.11 | |||||||
Vested | (147,434) | 23.05 | |||||||
Forfeited | (14,925) | 23.45 | |||||||
Nonvested at | December 31, 2010 | 123,386 | 22.57 | ||||||
Granted | 31,625 | 23.49 | |||||||
Vested | (80,825) | 22.80 | |||||||
Forfeited | (4,244) | 22.98 | |||||||
Nonvested at | December 30, 2011 | 69,942 | $ | 22.69 |
Performance-vested restricted stock granted prior to 2010 vests upon the achievement of certain annual diluted EPS targets by the Company, or the seventh anniversary date of the award.
The performance-based restricted stock units granted in 2010 and 2011 only vest if certain market-based performance metrics are achieved. The amount of shares that ultimately vest range from 0 shares to 513,243 shares based upon the total shareholder return of the Company relative to the Company's compensation peer group over a three year performance period beginning in the year of grant. The fair value of the restricted stock units was determined by utilizing a Monte Carlo simulation model, which projects the value of Greatbatch stock versus the peer group under numerous scenarios and determines the value of the award based upon the present value of these projected outcomes. The following table summarizes performance-vested restricted stock and stock unit activity related to the Company's plans:
Performance-Vested Activity | Weighted Average Fair Value | ||||||||
Nonvested at | January 2, 2009 | 24,000 | $ | 23.07 | |||||
Nonvested at | January 1, 2010 | 24,000 | 23.07 | ||||||
Granted | 289,654 | 14.43 | |||||||
Vested | (21,558) | 15.12 | |||||||
Forfeited | (8,299) | 14.56 | |||||||
Nonvested at | December 31, 2010 | 283,797 | 15.10 | ||||||
Granted | 279,415 | 18.21 | |||||||
Vested | (6,600) | 17.94 | |||||||
Forfeited | (26,869) | 15.85 | |||||||
Nonvested at | December 30, 2011 | 529,743 | $ | 16.68 |
The realized tax benefit (expense) from the vesting of restricted stock and restricted stock units was $0.008 million, $0.01 million and ($0.1 million) for 2011, 2010 and 2009, respectively. As of December 30, 2011, there was $6.0 million of total unrecognized compensation cost related to the restricted stock and restricted stock unit awards. That cost is expected to be recognized over a weighted-average period of approximately 2 years. The fair value of shares vested in 2011, 2010 and 2009 was $1.9 million, $4.1 million and $2.0 million, respectively.
|
11. RESEARCH, DEVELOPMENT AND ENGINEERING COSTS, NET
Research, Development and Engineering Costs, Net are comprised of the following (in thousands): | |||||||||||
Year Ended | |||||||||||
December 30, | December 31, | January 1, | |||||||||
2011 | 2010 | 2010 | |||||||||
Research and development costs | $ | 19,014 | $ | 17,378 | $ | 17,707 | |||||
Engineering costs | 35,472 | 34,208 | 26,438 | ||||||||
Less: cost reimbursements | (8,973) | (6,567) | (10,583) | ||||||||
Engineering costs, net | 26,499 | 27,641 | 15,855 | ||||||||
Total research, development and | |||||||||||
engineering costs, net | $ | 45,513 | $ | 45,019 | $ | 33,562 |
|
12. OTHER OPERATING EXPENSES, NET
Other Operating Expenses, Net is comprised of the following (in thousands): | |||||||||
Year Ended | |||||||||
December 30, | December 31, | January 1, | |||||||
2011 | 2010 | 2010 | |||||||
Orthopaedic facility optimization(a) | $ | 425 | $ | 225 | $ | - | |||
2007 & 2008 facility shutdowns and consolidations(b) | - | 1,348 | 7,069 | ||||||
Integration costs(c) | - | 42 | 3,077 | ||||||
Asset dispositions, severance and other(d) | 168 | 2,943 | 948 | ||||||
$ | 593 | $ | 4,558 | $ | 11,094 |
(a) Orthopaedic facility optimization. In 2010, the Company began updating its Indianapolis, IN facility to streamline operations, consolidate two buildings, increase capacity, further expand capabilities and reduce dependence on outside suppliers. This initiative was completed in 2011.
In 2011, the Company began construction on an 80,000 square foot manufacturing facility in Allen County, IN and will transfer the manufacturing operations currently being performed at its Columbia City, IN location into this new facility. This facility is expected to be completed by mid-2012.
In 2011, the Company also initiated a multi-faceted plan to further enhance, optimize and leverage the Company's Orthopaedics manufacturing infrastructure. This plan includes the opening of two Orthopaedic design centers, transferring production of certain Orthopaedic product lines to other lower cost manufacturing facilities and the consolidation of the Company's Orthopaedic operations in Switzerland into a new facility. These initiatives are expected to be completed over the next two to three years.
The total capital investment expected to be incurred for these initiatives is between $50 million and $60 million, of which $13 million has been incurred. Total expense expected to be incurred for these initiatives is between $10 million and $15 million, of which $1 million has been incurred. All expenses will be recorded within the Greatbatch Medical segment and are expected to include the following:
Ultimately these updates will further reduce lead times, improve quality and allow the Company to better meet the needs of its customers. All expenses are cash expenditures, except accelerated depreciation and asset write-offs.
The change in accrued liabilities related to the Orthopaedic facility optimizations is as follows (in thousands): | |||||||||||||||||
Severance and Retention | Production Inefficiencies, Moving and Revalidation | Accelerated Depreciation/Asset Write-offs | Other | Total | |||||||||||||
At | December 31, 2010 | $ | - | $ | - | $ | - | $ | - | $ | - | ||||||
Restructuring charges | - | 397 | 18 | 10 | 425 | ||||||||||||
Write-offs | - | - | (18) | - | (18) | ||||||||||||
Cash payments | - | (397) | - | (10) | (407) | ||||||||||||
At | December 30, 2011 | $ | - | $ | - | $ | - | $ | - | $ | - |
(b) 2007 & 2008 facility shutdowns and consolidations. From 2007 to 2010, the Company completed the following facility shutdowns and consolidation initiatives:
The total expenses incurred for these facility shutdowns and consolidations was $17.3 million and included the following:
All categories of costs are considered to be cash expenditures, except accelerated depreciation and asset write-offs. For 2010, costs relating to these initiatives of $0.3 million and $1.0 million were included in the Greatbatch Medical and Electrochem business segments, respectively. For 2009, costs relating to these initiatives of $1.6 million and $5.5 million were included in the Greatbatch Medical and Electrochem business segments, respectively.
As a result of these consolidation initiatives, two Greatbatch Medical facilities and one Electrochem facility were classified as assets held for sale. One Greatbatch Medical and one Electrochem facility were sold in 2010, which resulted in net cash proceeds of $2.4 million. The remaining Greatbatch Medical facility, which had a fair value of $1.9 million, was reclassified to Property, Plant and Equipment, Net in 2010 as management decided to utilize this facility for future operations. For 2010 and 2009 write-downs of $1.0 million and $0.3 million, respectively, were recorded relating to these facilities and were included in Other Operating Expenses, Net.
(c) Integration costs. During 2010 and 2009, the Company incurred costs related to the integration of the companies acquired in 2007 and 2008. The integration initiatives include the implementation of the Oracle ERP system, training and compliance with Company policies, as well as the implementation of lean manufacturing and six sigma initiatives. These expenses were primarily for consultants, relocation and travel costs.
(d) Asset dispositions, severance and other. During 2011, 2010, and 2009, the Company recorded (gains) write-downs in connection with various asset disposals, net of insurance proceeds received, if any. Additionally, during 2011 the Company incurred $0.6 million of acquisition related costs in connection with its purchase of Micro Power. During 2010, we realigned resources within Greatbatch Medical, which included the elimination of certain positions globally. Severance charges associated with this realignment were $2.3 million. A significant portion of the annual savings as a result of this initiative was reinvested into research and development activities with higher growth opportunities, including further investment in the Company's systems and device projects. During 2009, the Company incurred approximately $0.6 million in severance charges in connection with various workforce reductions.
|
13. INCOME TAXES
The U.S. and international components of income (loss) before provision (benefit) for income taxes were as follows (in thousands):
Year Ended | |||||||||
December 30, | December 31, | January 1, | |||||||
2011 | 2010 | 2010 | |||||||
U.S. | $ | 43,610 | $ | 46,217 | $ | (15,285) | |||
International | 4,782 | 3,108 | (2,892) | ||||||
$ | 48,392 | $ | 49,325 | $ | (18,177) |
The provision (benefit) for income taxes was comprised of the following (in thousands): | ||||||||||
Year Ended | ||||||||||
December 30, | December 31, | January 1, | ||||||||
2011 | 2010 | 2010 | ||||||||
Current: | ||||||||||
Federal | $ | 5,150 | $ | (671) | $ | 827 | ||||
State | (40) | 179 | (177) | |||||||
International | 1,384 | 1,260 | 294 | |||||||
6,494 | 768 | 944 | ||||||||
Deferred: | ||||||||||
Federal | 8,028 | 15,409 | (9,256) | |||||||
State | 599 | 300 | (153) | |||||||
International | 149 | (290) | (711) | |||||||
8,776 | 15,419 | (10,120) | ||||||||
$ | 15,270 | $ | 16,187 | $ | (9,176) |
The provision (benefit) for income taxes differs from the U.S. statutory rate due to the following: | |||||||||
Year Ended | |||||||||
December 30, | December 31, | January 1, | |||||||
2011 | 2010 | 2010 | |||||||
Statutory rate | 35.0 | % | 35.0 | % | (35.0) | % | |||
Federal tax credits | (3.7) | (2.6) | (5.5) | ||||||
Foreign rate differential | 0.3 | (0.8) | 1.9 | ||||||
Uncertain tax positions | (1.3) | (1.3) | (7.8) | ||||||
State taxes, net of federal benefit | 0.3 | (0.3) | (1.2) | ||||||
Valuation allowance | 0.1 | 1.7 | (0.1) | ||||||
Other | 0.9 | 1.1 | (2.8) | ||||||
Effective tax rate | 31.6 | % | 32.8 | % | (50.5) | % |
In its budget submission to Congress in February 2012, the Obama administration proposed changes to the manner in which the U.S. would tax the international income of U.S. based companies. While it is uncertain how the U.S. Congress will address U.S. tax policy in the future, reform of U.S. taxation, including taxation of international income, continues to be a topic of discussion for Congress. A significant change to the U.S. tax system, including changes to the taxation of international income, could have a material effect on the Company's effective tax rate.
Deferred tax assets (liabilities) consist of the following (in thousands): | ||||||
At | ||||||
December 30, | December 31, | |||||
2011 | 2010 | |||||
Tax credits | $ | 7,362 | $ | 5,896 | ||
Net operating loss carryforwards | 11,106 | 4,617 | ||||
Inventories | 4,441 | 4,575 | ||||
Accrued expenses | 2,961 | 2,563 | ||||
Stock-based compensation | 6,378 | 5,358 | ||||
Other | 1,052 | 507 | ||||
Gross deferred tax assets | 33,300 | 23,516 | ||||
Less valuation allowance | (7,775) | (6,482) | ||||
Net deferred tax assets | 25,525 | 17,034 | ||||
Property, plant and equipment | (2,572) | (713) | ||||
Intangible assets | (54,874) | (40,082) | ||||
Convertible subordinated notes | (33,849) | (31,218) | ||||
Gross deferred tax liabilities | (91,295) | (72,013) | ||||
Net deferred tax liability | $ | (65,770) | $ | (54,979) | ||
Presented as follows: | ||||||
Current deferred tax asset | $ | 7,828 | $ | 7,398 | ||
Current deferred tax liability | (845) | (514) | ||||
Noncurrent deferred tax asset | 2,450 | 2,427 | ||||
Noncurrent deferred tax liability | (75,203) | (64,290) | ||||
$ | (65,770) | $ | (54,979) |
As of December 30, 2011, the Company has the following carryforwards available:
Tax | Amount | Begin to | |||||
Jurisdiction | Attribute | (in millions) | Expire | ||||
U.S. | Net Operating Loss | $ | 19.2(1) | 2025 | |||
Switzerland | Net Operating Loss | 12.3(1) | 2012 | ||||
State | Net Operating Loss | 29.1(1) | Various | ||||
U.S. and State | R&D Credit | 1.9(1) | Various | ||||
State | Investment Tax Credit | 5.3 | Various |
Certain federal tax credits reported on filed income tax returns included uncertain tax positions taken in prior years. Due to the application of the accounting for uncertain tax positions, the actual tax attributes are larger than the tax credits for which a deferred tax asset is recognized for financial statement purposes.
In assessing the realizability of deferred tax assets, management considers, within each taxing jurisdiction, whether it is more likely than not that some portion or all of the deferred tax assets will not be realized. Management considers the scheduled reversal of deferred tax liabilities, projected future taxable income and tax planning strategies in making this assessment. Based on the consideration of the weight of both positive and negative evidence, management has determined that a portion of the deferred tax assets as of December 30, 2011 and December 31, 2010 related to certain state investment tax credits and net operating losses will not be realized.
The Company files annual income tax returns in the U.S., various state and local jurisdictions, and in various foreign jurisdictions. A number of years may elapse before an uncertain tax position, for which the Company has unrecognized tax benefits, is examined and finally settled. While it is often difficult to predict the final outcome or the timing of resolution of any particular uncertain tax position, the Company believes that its unrecognized tax benefits reflect the most probable outcome. The Company adjusts these unrecognized tax benefits, as well as the related interest, in light of changing facts and circumstances. The resolution of a matter could be recognized as an adjustment to the provision for income taxes and the effective tax rate in the period of resolution.
Below is a summary of changes to the unrecognized tax benefit (in thousands): | |||||||||
Year Ended | |||||||||
December 30, | December 31, | January 1, | |||||||
2011 | 2010 | 2010 | |||||||
Balance, beginning of year | $ | 2,756 | $ | 3,418 | $ | 5,686 | |||
Additions based upon tax positions related to the current year | 300 | 300 | 396 | ||||||
Additions recorded as part of business combinations | 260 | - | - | ||||||
Additions (reductions) related to prior period tax positions | - | 222 | (1,185) | ||||||
Reductions relating to settlements with tax authorities | - | - | (700) | ||||||
Reductions as a result of a lapse of applicable | |||||||||
statute of limitations | (1,736) | (1,184) | (779) | ||||||
Balance, end of year | $ | 1,580 | $ | 2,756 | $ | 3,418 |
The tax years that remain open and subject to tax audits varies depending on the tax jurisdiction. The consolidated Federal 2009 and 2010 tax returns are currently under audit. The 2008 Federal tax return remains open for examination. The Company is also under audit in France for 2009 and 2010.
It is reasonably possible that a reduction of approximately $0.8 million of the balance of unrecognized tax benefits may occur within the next 12 months as a result of the lapse of the statute of limitations and potential audit settlements. As of December 30, 2011, approximately $1.5 million of unrecognized tax benefits would favorably impact the effective tax rate (net of federal benefit on state issues), if recognized.
|
14. COMMITMENTS AND CONTINGENCIES
Litigation – The Company is a party to various legal actions arising in the normal course of business. The majority of these claims are employment related matters with former employees of the Company. While the Company does not believe that the ultimate resolution of any individual pending action will have a material effect on its results of operations, financial position, or cash flows, litigation is subject to inherent uncertainties. If an unfavorable ruling(s) were to occur, there exists the possibility of a material impact in the period in which the ruling occurs.
Previously reported - in 2002, a former Electrochem customer, Input/Output, Inc., now known as ION Geophysical Corporation (“Input/Output”), commenced an action against the Company. After trial in September 2009, a jury found in favor of Input/Output on fraud, unfair trade practices and breach of contract claims and awarded damages in the amount of $21.7 million. The final judgment in the matter included an award of prejudgment interest bringing the total judgment to approximately $33 million. During 2009, the Company accrued $34.5 million in connection with the Electrochem Litigation. The Company's post-trial motion for a new trial was denied, and the Company appealed the judgment to the Louisiana Court of Appeal. In December 2010, the Company entered into a settlement agreement with Input/Output. Under terms of this agreement, Input/Output released the Company of any liability in connection with the jury verdict and in return for that release, the Company paid Input/Output $25 million. In the fourth quarter of 2010, the Company recognized a gain for the remaining $9.5 million of the previous accrual.
License agreements – The Company is a party to various license agreements for technology that is utilized in certain of its products. The most significant of these agreements are the licenses for basic technology used in the production of wet tantalum capacitors, filtered feedthroughs and MRI compatible lead systems. Expenses related to license agreements were $2.8 million, $2.5 million and $3.3 million, for 2011, 2010 and 2009, respectively, and are included in Cost of Sales.
Product Warranties – The Company generally warrants that its products will meet customer specifications and will be free from defects in materials and workmanship. The Company accrues its estimated exposure to warranty claims based upon recent historical experience and other specific information as it becomes available.
The change in product warranty liability was comprised of the following (in thousands): | |||||||
Year Ended | |||||||
December 30, | December 31, | ||||||
2011 | 2010 | ||||||
Beginning balance | $ | 2,313 | $ | 1,330 | |||
Warranty reserves acquired | 210 | 0 | |||||
Additions to warranty reserve | 375 | 2,237 | |||||
Warranty claims paid | (887) | (1,285) | |||||
Foreign currency effect | 2 | 31 | |||||
Ending balance | $ | 2,013 | $ | 2,313 |
Operating Leases – The Company is a party to various operating lease agreements for buildings, equipment and software. The Company primarily leases buildings, which accounts for the majority of the future lease payments. Lease expense includes the effect of escalation clauses and leasehold improvement incentives which are accounted for ratably over the lease term.
Operating lease expense was as follows (in thousands): | |||||||||
Year Ended | |||||||||
December 30, | December 31, | January 1, | |||||||
2011 | 2010 | 2010 | |||||||
Operating lease expense | $ | 2,704 | $ | 3,114 | $ | 3,443 |
Minimum future estimated annual operating lease expense are as follows (in thousands): | ||||
2012 | $ | 3,347 | ||
2013 | 2,832 | |||
2014 | 2,849 | |||
2015 | 2,466 | |||
2016 | 2,305 | |||
Thereafter | 2,895 | |||
Total estimated operating lease expense | $ | 16,694 |
Self-Insured Medical Plan – Beginning in 2010, the Company began self-funding the medical insurance coverage provided to its U.S. based employees. The risk to the Company is being limited through the use of stop loss insurance, which has an annual deductible of $0.2 million per covered participant. The maximum aggregate loss (the sum of all claims under the $0.2 million deductible) is limited to $14.2 million with a maximum benefit of $1.0 million. As of December 30, 2011 and December 31, 2010, the Company had $1.6 million and $2.1 million accrued, related to the self-insurance of its medical plan, respectively. This accrual is recorded in Accrued Expenses in the Consolidated Balance Sheet, and is primarily based upon claim history. For 2012, the maximum aggregate loss limit was lowered to $13.5 million.
Purchase Commitments – Contractual obligations for purchase of goods or services are defined as agreements that are enforceable and legally binding on the Company and that specify all significant terms, including: fixed or minimum quantities to be purchased; fixed, minimum or variable price provisions; and the approximate timing of the transaction. Our purchase orders are normally based on our current capital and manufacturing needs and are fulfilled by our vendors within short time horizons. We enter into blanket orders with vendors that have preferred pricing and terms, however these orders are normally cancelable by us without penalty. As of December 30, 2011, the total contractual obligation related to such expenditures is approximately $31.6 million and will primarily be financed by existing cash and cash equivalents, cash generated from operations, or the 2011 Credit Facility over the next twelve months. We also enter into contracts for outsourced services; however, the obligations under these contracts were not significant and the contracts generally contain clauses allowing for cancellation without significant penalty.
Foreign Currency Contracts – The Company has entered into forward contracts to purchase Mexican pesos in order to hedge the risk of peso-denominated payments associated with the operations at its Tijuana, Mexico facility.
Reduction in Cost of Sales related to the Company’s forward contracts are as follows (in thousands): | ||||||||||
Year Ended | ||||||||||
December 30, | December 31, | January 1, | ||||||||
2011 | 2010 | 2010 | ||||||||
Reduction in Cost of Sales | $ | 556 | $ | 483 | $ | 559 | ||||
Ineffective portion of change in fair value | 0 | 0 | 0 |
Information regarding the Company's outstanding foreign currency contracts as of December 30, 2011 is as follows (dollars in thousands): | |||||||||||||||||
Aggregate | |||||||||||||||||
Type of | Notional | Start | End | Fair | Balance Sheet | ||||||||||||
Instrument | Hedge | Amount | Date | Date | Pesos/$ | Value | Location | ||||||||||
FX Contract | Cash flow | $ | 6,000 | Jan-12 | Dec-12 | 13.0354 | $ | (486) | Accrued Exp | ||||||||
FX Contract | Cash flow | $ | 4,200 | Jan-12 | Dec-12 | 14.0287 | (52) | Accrued Exp | |||||||||
$ | (538) |
Workers' Compensation Trust – The Company was a member of a group self-insurance trust that provided workers' compensation benefits to employees of the Company in Western New York (the “Trust”). Under the Trust agreement, each participating organization has joint and several liability for Trust obligations if the assets of the Trust are not sufficient to cover those obligations. During 2011, the Company was notified by the Trust of its intentions to cease operations at the end of 2011 and was assessed $0.6 million as an estimate of its pro-rata share of future costs related to the Trust. This amount was accrued and paid in 2011. Based on actual experience, the Company could receive a refund or be assessed additional contributions for workers' compensation claims. Beginning in 2012, the Company will utilize traditional insurance to provide workers' compensation benefits.
|
16. ACCUMULATED OTHER COMPREHENSIVE INCOME
Accumulated Other Comprehensive Income is comprised of the following (in thousands): | ||||||||||||||||||
Defined Benefit Plan Liability | Cash Flow Hedges | Foreign Currency Translation Adjustment | Total Pre-Tax Amount | Tax | Net-of-Tax Amount | |||||||||||||
At | December 31, 2010 | $ | (2,014) | $ | (121) | $ | 12,230 | $ | 10,095 | $ | 375 | $ | 10,470 | |||||
Unrealized loss on cash flow hedges | - | (303) | - | (303) | 106 | (197) | ||||||||||||
Realized gain on cash flow hedges | - | (114) | - | (114) | 40 | (74) | ||||||||||||
Net defined benefit plan | ||||||||||||||||||
liability adjustments | (646) | - | - | (646) | 80 | (566) | ||||||||||||
Foreign currency translation gain | - | - | (704) | (704) | - | (704) | ||||||||||||
At | December 30, 2011 | $ | (2,660) | $ | (538) | $ | 11,526 | $ | 8,328 | $ | 601 | $ | 8,929 |
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17. FAIR VALUE MEASUREMENTS
Assets and Liabilities Measured at Fair Value on a Recurring Basis
Fair value measurement standards apply to certain financial assets and liabilities that are measured at fair value on a recurring basis (each reporting period). For the Company, these financial assets and liabilities include its derivative instruments. The Company does not have any nonfinancial assets or liabilities that are measured at fair value on a recurring basis. A summary of the valuation methodologies for assets and liabilities measured on a recurring basis is as follows:
Foreign currency contracts - The fair value of foreign currency contracts outstanding at December 30, 2011 and December 31, 2010 were determined through the use of cash flow models that utilize observable market data inputs to estimate fair value. These observable market data inputs include spot and forward foreign currency exchange rates, interest rates and credit spread curves. In addition to the above, the Company received fair value estimates from the foreign currency contract counterparty to verify the reasonableness of the Company's estimates. These fair value calculations are categorized in Level 2 of the fair value hierarchy.
Interest rate swap - The fair value of the Company's interest rate swap outstanding at December 31, 2010 was determined through the use of a cash flow model that utilizes observable market data inputs. These observable market data inputs include LIBOR, swap rates, and credit spread curves. In addition to the above, the Company received a fair value estimate from the interest rate swap counterparty to verify the reasonableness of the Company's estimate. This fair value calculation was categorized in Level 2 of the fair value hierarchy.
The following tables provide information regarding assets and liabilities recorded at fair value on a recurring basis (in thousands): | |||||||||||||
Fair Value Measurements Using | |||||||||||||
Quoted | |||||||||||||
Prices in | Significant | ||||||||||||
Active Markets | Other | Significant | |||||||||||
At | for Identical | Observable | Unobservable | ||||||||||
December 30, | Assets | Inputs | Inputs | ||||||||||
Description | 2011 | (Level 1) | (Level 2) | (Level 3) | |||||||||
Liabilities | |||||||||||||
Foreign currency contracts (Note 14) | $ | 538 | $ | - | $ | 538 | $ | - | |||||
Fair Value Measurements Using | |||||||||||||
Quoted | |||||||||||||
Prices in | Significant | ||||||||||||
Active Markets | Other | Significant | |||||||||||
At | for Identical | Observable | Unobservable | ||||||||||
December 31, | Assets | Inputs | Inputs | ||||||||||
Description | 2010 | (Level 1) | (Level 2) | (Level 3) | |||||||||
Assets | |||||||||||||
Foreign currency contracts | $ | 315 | $ | - | $ | 315 | $ | - | |||||
Liabilities | |||||||||||||
Interest rate swap | $ | 436 | $ | - | $ | 436 | $ | - |
Assets and Liabilities Measured at Fair Value on a Nonrecurring Basis
Fair value standards also apply to certain nonfinancial assets and liabilities that are measured at fair value on a nonrecurring basis. For example, certain long-lived assets such as goodwill, intangible assets, cost method investments and property, plant and equipment are measured at fair value when an impairment is recognized and the related assets are written down to fair value. A summary of the valuation methodologies for assets and liabilities measured on a nonrecurring basis is as follows:
Cost method investment - The Company holds investments in equity securities that are accounted for as cost method investments, which are classified as Other Long-Term Assets, and are measured at fair value only if certain events or circumstances occur that have a significant effect on the fair value of the investment. The aggregate recorded amount of cost method investments at December 30, 2011 and December 31, 2010 was $5.7 million and $11.8 million, respectively. During 2011 and 2010, the Company recognized impairment charges related to its cost method investments of $0.3 million and $0.2 million, respectively. The fair value of these investments was determined by reference to recent sales data of similar shares to independent parties in an inactive market. This fair value calculation was categorized in Level 2 of the fair value hierarchy.
On January 5, 2011, the Company sold its cost method investment in IntElect Medical, Inc. (“IntElect”) in conjunction with Boston Scientific's acquisition of IntElect. This transaction resulted in a pre-tax gain of $4.5 million.
Property, plant and equipment, net - During 2010, one Greatbatch Medical facility, which was previously classified as an asset held for sale, was reclassified to Property, Plant and Equipment, Net as management decided to utilize this facility for future operations. This building was recorded at fair value at the date of reclassification and is now being amortized on a straight-line basis over its remaining estimated useful life. The fair value was determined by reference to recent sales data for comparable facilities. This fair value calculation was categorized in Level 2 of the fair value hierarchy.
The following table provides information regarding assets and liabilities recorded at fair value on a nonrecurring basis. There were no such assets or liabilities as of December 30, 2011 (in thousands): | |||||||||||||
Fair Value Measurements Using | |||||||||||||
Quoted | |||||||||||||
Prices in | Significant | ||||||||||||
Active Markets | Other | Significant | |||||||||||
At | for Identical | Observable | Unobservable | ||||||||||
December 31, | Assets | Inputs | Inputs | ||||||||||
Description | 2010 | (Level 1) | (Level 2) | (Level 3) | |||||||||
Assets | |||||||||||||
Property, plant and equipment, net (Note 12) | $ | 1,908 | $ | - | $ | 1,908 | $ | - | |||||
Cost method investment | 317 | - | 317 | - |
Fair Value of Other Financial Instruments
Convertible subordinated notes - The fair value of the Company's convertible subordinated notes disclosed in Note 8 “Debt” was determined based upon recent third-party transactions for the Company's notes in an inactive market. The Company's convertible subordinated notes are valued for disclosure purposes utilizing Level 2 measurements of the fair value hierarchy.
Pension plan assets – The fair value of the Company's pension plan assets disclosed in Note 9 “Employee Benefit Plans” are determined based upon quoted market prices in active markets, quoted market prices in inactive markets or multidimensional relational models with observable market data inputs to estimate fair value. These observable market data inputs include benchmark yields, reported trades, broker/dealer quotes, issuer spreads, benchmark securities, bids, offers and reference data. The Company's pension plan assets are categorized in Level 1 or Level 2 of the fair value hierarchy.
|
18. STOCKHOLDER RIGHTS PLAN
On March 1, 2002, the Company's Board of Directors adopted a stockholder rights plan and declared a dividend distribution of one preferred stock purchase right for each outstanding share of common stock. The dividend was paid to stockholders as of April 30, 2002. Each right, once exercisable, entitles the registered holder to purchase from the Company one one-hundredth of a share of preferred stock of the Company.
Under the rights plan, the rights initially trade together with the common stock and are not exercisable. In the absence of further action by the Board of Directors, the rights will become exercisable if a person or group acquires 15 percent or more of the outstanding shares of common stock or a person or group announces its intent to commence a tender or exchange offer without the prior approval of the Board of Directors.
The rights plan includes an exchange option. In general, after the rights become exercisable, the Board of Directors may, at its option, affect an exchange of part or all of the rights at a ratio of one share of Common Stock for each right, subject to adjustment in certain circumstances. The rights are also redeemable at any time prior to the time they become exercisable for $0.001 per right, subject to adjustment in certain circumstances.
Unless earlier amended, redeemed or exchanged, the rights will expire on March 18, 2012. The issuance of the rights was not a taxable event, does not affect our reported financial condition or results of operations, including our EPS, and does not change the manner in which our common stock is traded.
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19. BUSINESS SEGMENT, GEOGRAPHIC AND CONCENTRATION RISK INFORMATION
The Company operates its business in two reportable segments – Greatbatch Medical and Electrochem Solutions (“Electrochem”). The Greatbatch Medical segment designs and manufactures medical devices and components primarily for the CRM, Neuromodulation, Vascular Access and Orthopaedic markets. Additionally, Greatbatch Medical offers value-added assembly and design engineering services for products that incorporate Greatbatch Medical components. As a result of the strategy put in place over three years ago, Greatbatch Medical now offers its customers complete medical devices including design, development, manufacturing, regulatory submission and supporting worldwide distribution. This medical device strategy is being facilitated through the Company's QiG Group and leverages the component technology of Greatbatch Medical and Electrochem in the Company's core markets: Cardiovascular, Neuromodulation and Orthopaedic. Once the QiG Group designs and develops a medical device, it is manufactured by Greatbatch Medical. The operating expenses (RD&E, SG&A) of the QiG Group are included within the Greatbatch Medical segment.
Electrochem designs, manufactures and distributes primary and rechargeable batteries, battery packs and wireless sensors for demanding applications in markets such as energy, security, portable medical, environmental monitoring and more.
The Company defines segment income from operations as sales less cost of sales including amortization and expenses attributable to segment-specific SG&A, RD&E expenses, and other operating expenses. Segment income also includes a portion of non-segment specific SG&A expenses based on allocations appropriate to the expense categories. The remaining unallocated operating and other expenses are primarily administrative corporate headquarters expenses and capital costs that are not allocated to reportable segments. Transactions between the two segments are not significant.
Significant charges (gains) included in the Company's business segment results are as follows (in thousands):
Year Ended | |||||||||||
December 30, | December 31, | January 1, | |||||||||
2011 | 2010 | 2010 | |||||||||
Greatbatch Medical | |||||||||||
Intangible asset write-down | $ | - | $ | - | $ | 15,921 | |||||
Electrochem | |||||||||||
Electrochem Litigation charge (gain) | - | (9,500) | 34,500 |
An analysis and reconciliation of the Company's business segment, product line and geographic information to the respective information in the Consolidated Financial Statements follows. Sales by geographic area are presented by allocating sales from external customers based on where the products are shipped to (in thousands):
Year Ended | |||||||||||
December 30, | December 31, | January 1, | |||||||||
Sales: | 2011 | 2010 | 2010 | ||||||||
Greatbatch Medical | |||||||||||
CRM/Neuromodulation | $ | 303,690 | $ | 303,521 | $ | 305,354 | |||||
Vascular Access | 45,098 | 38,000 | 35,816 | ||||||||
Orthopaedic | 140,277 | 118,748 | 113,897 | ||||||||
Total Greatbatch Medical | 489,065 | 460,269 | 455,067 | ||||||||
Electrochem | 79,757 | 73,156 | 66,754 | ||||||||
Total sales | $ | 568,822 | $ | 533,425 | $ | 521,821 |
Year Ended | |||||||||||
December 30, | December 31, | January 1, | |||||||||
2011 | 2010 | 2010 | |||||||||
Segment income (loss) from operations: | |||||||||||
Greatbatch Medical | $ | 62,461 | $ | 62,477 | $ | 46,270 | |||||
Electrochem | 14,965 | 22,195 | (32,734) | ||||||||
Total segment income from operations | 77,426 | 84,672 | 13,536 | ||||||||
Unallocated operating expenses | (15,727) | (15,678) | (12,488) | ||||||||
Operating income as reported | 61,699 | 68,994 | 1,048 | ||||||||
Unallocated other expense | (13,307) | (19,669) | (19,225) | ||||||||
Income (loss) before provision (benefit) for | |||||||||||
income taxes as reported | $ | 48,392 | $ | 49,325 | $ | (18,177) |
Year Ended | |||||||||||
December 30, | December 31, | January 1, | |||||||||
2011 | 2010 | 2010 | |||||||||
Depreciation and Amortization: | |||||||||||
Greatbatch Medical | $ | 28,571 | $ | 28,117 | $ | 29,869 | |||||
Electrochem | 2,965 | 2,660 | 2,860 | ||||||||
Total depreciation and amortization included | |||||||||||
in segment income from operations | 31,536 | 30,777 | 32,729 | ||||||||
Unallocated depreciation and amortization | 16,159 | 15,670 | 14,500 | ||||||||
Total depreciation and amortization | $ | 47,695 | $ | 46,447 | $ | 47,229 |
Year Ended | |||||||||||
December 30, | December 31, | January 1, | |||||||||
2011 | 2010 | 2010 | |||||||||
Expenditures for tangible long-lived assets, | |||||||||||
excluding acquisitions: | |||||||||||
Greatbatch Medical | $ | 22,509 | $ | 15,088 | $ | 11,261 | |||||
Electrochem | 1,072 | 763 | 910 | ||||||||
Total reportable segments | 23,581 | 15,851 | 12,171 | ||||||||
Unallocated long-lived tangible assets | 741 | 1,120 | 7,040 | ||||||||
Total expenditures | $ | 24,322 | $ | 16,971 | $ | 19,211 |
At | ||||||||
December 30, | December 31, | |||||||
2011 | 2010 | |||||||
Identifiable assets, net: | ||||||||
Greatbatch Medical | $ | 653,628 | $ | 641,591 | ||||
Electrochem | 161,904 | 71,480 | ||||||
Total reportable segments | 815,532 | 713,071 | ||||||
Unallocated assets | 65,815 | 63,905 | ||||||
Total assets | $ | 881,347 | $ | 776,976 |
Year Ended | |||||||||||
December 30, | December 31, | January 1, | |||||||||
2011 | 2010 | 2010 | |||||||||
Sales by geographic area: | |||||||||||
United States | $ | 256,987 | $ | 243,827 | $ | 245,974 | |||||
Non-Domestic locations: | |||||||||||
Puerto Rico | 94,059 | 88,369 | 76,823 | ||||||||
Belgium | 62,978 | 58,014 | 29,431 | ||||||||
United Kingdom & Ireland | 54,029 | 56,903 | 66,255 | ||||||||
France | 5,700 | 6,318 | 37,373 | ||||||||
Rest of world | 95,069 | 79,994 | 65,965 | ||||||||
Total sales | $ | 568,822 | $ | 533,425 | $ | 521,821 |
At | ||||||
December 30, | December 31, | |||||
Long-lived tangible assets: | 2011 | 2010 | ||||
United States | $ | 113,693 | $ | 126,519 | ||
Rest of world | 32,113 | 36,095 | ||||
Total | $ | 145,806 | $ | 162,614 |
A significant portion of the Company’s sales and accounts receivable were to four customers as follows: | ||||||||||||
Sales | Accounts Receivable | |||||||||||
Year Ended | At | |||||||||||
December 30, | December 31, | January 1, | December 30, | December 31, | ||||||||
2011 | 2010 | 2010 | 2011 | 2010 | ||||||||
Customer A | 19% | 21% | 22% | 7% | 15% | |||||||
Customer B | 19% | 19% | 17% | 23% | 13% | |||||||
Customer C | 13% | 12% | 12% | 6% | 8% | |||||||
Customer D | 8% | 10% | 12% | 6% | 14% | |||||||
59% | 62% | 63% | 42% | 50% |
|
20. QUARTERLY SALES AND EARNINGS DATA - UNAUDITED
4th Qtr. | 3rd Qtr. | 2nd Qtr. | 1st Qtr. | |||||||||
(in thousands, except per share data) | ||||||||||||
2011 | ||||||||||||
Sales | $ | 141,746 | $ | 131,718 | $ | 146,524 | $ | 148,834 | ||||
Gross profit | 44,672 | 41,907 | 46,604 | 47,170 | ||||||||
Net income(1) | 5,639 | 6,989 | 8,550 | 11,944 | ||||||||
EPS - basic | 0.24 | 0.30 | 0.37 | 0.51 | ||||||||
EPS - diluted | 0.24 | 0.30 | 0.36 | 0.51 | ||||||||
2010 | ||||||||||||
Sales | $ | 133,111 | $ | 127,490 | $ | 140,795 | $ | 132,029 | ||||
Gross profit | 44,464 | 41,994 | 45,459 | 41,664 | ||||||||
Net income(2) | 13,839 | 5,964 | 7,788 | 5,547 | ||||||||
EPS - basic | 0.60 | 0.26 | 0.34 | 0.24 | ||||||||
EPS - diluted | 0.59 | 0.25 | 0.33 | 0.24 |
(1) Net income in the 2011 first quarter includes the impact of the gain on sale of a cost method investment. See Note 17 “Fair Value Measurements.”
(2) Net income in the 2010 fourth quarter includes the impact of the Electrochem Litigation gain. See Note 14 “Commitments and Contingencies.”
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Schedule II - Valuation and Qualifying Accounts | |||||||||||||||||
Col. C - Additions | |||||||||||||||||
Col. B | Charged to | Col. E | |||||||||||||||
Balance at | Charged to | Other | Col. D | Balance at | |||||||||||||
Col. A | Beginning | Costs & | Accounts - | Deductions - | End | ||||||||||||
Description | of Period | Expenses | Describe | Describe | of Period | ||||||||||||
December 30, 2011 | |||||||||||||||||
Allowance for | |||||||||||||||||
doubtful accounts | $ | 1,830 | $ | 288 | $ | 170(3)(4) | $ | (358)(2) | $ | 1,930 | |||||||
Valuation allowance | |||||||||||||||||
for deferred income | |||||||||||||||||
tax assets | $ | 6,482 | $ | 702(1) | $ | 591(3)(4) | $ | - | $ | 7,775 | |||||||
December 31, 2010 | |||||||||||||||||
Allowance for | |||||||||||||||||
doubtful accounts | $ | 2,452 | $ | (64) | $ | 35(4) | $ | (593)(2) | $ | 1,830 | |||||||
Valuation allowance | |||||||||||||||||
for deferred income | |||||||||||||||||
tax assets | $ | 5,656 | $ | 761(1) | $ | 65(4) | $ | - | $ | 6,482 | |||||||
January 1, 2010 | |||||||||||||||||
Allowance for | |||||||||||||||||
doubtful accounts | $ | 1,603 | $ | 961 | $ | - | $ | (112)(2) | $ | 2,452 | |||||||
Valuation allowance | |||||||||||||||||
for deferred income | |||||||||||||||||
tax assets | $ | 4,485 | $ | 1,171(1) | $ | - | $ | - | $ | 5,656 |