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Rationalizations and Impairments
6 Months Ended
Jun. 30, 2015
Restructuring and Related Activities [Abstract]  
Rationalizations and Impairments
Rationalizations and Impairments
Throughout 2013, 2014 and 2015 the Company undertook rationalization plans in order to streamline our organization and lower our production costs. The total rationalization and related charges incurred during the three and six months ended June 30, 2014 and 2015 are as follows:
All Plans
 
For the Three Months Ended June 30, 2014
 
For the Three Months Ended June 30, 2015
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
 
 
 
 
 
 
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
 
 
 
 
 
 
 
 
Accelerated
   depreciation
 
 
$
3,832

 
$
413

 
$

 
$
4,245

 
$

 
$

 
$

 
$

Inventory loss
 
(148
)
 
11,057

 

 
10,909

 

 
144

 

 
144

Fixed asset
   write-offs
     and other
 
4,403

 
131

 

 
4,534

 
413

 
1,072

 

 
1,485

Recorded in Research and Development
 
 
 
 
 
 
 
 
 
 
Accelerated
   depreciation
 
 

 

 

 

 

 

 
319

 
319

Recorded in Selling and General Administrative
 
 
 
 
 
 
 
 
 
 
Other
 
53

 

 

 
53

 
400

 
292

 
(276
)
 
416

Recorded in Rationalizations
 
 
 
 
 
 
 
 
 
 
Severance
  and related
    costs
 
304

 

 

 
304

 
104

 
1,641

 
(130
)
 
1,615

Contract terminations
 
527

 

 

 
527

 

 
154

 

 
154

Total
 
$
8,971

 
$
11,601

 
$

 
$
20,572

 
$
917

 
$
3,303

 
$
(87
)
 
$
4,133

In the three months ended June 30, 2015, in connection with our rationalization initiatives, two sites, located respectively in Salvador, Brazil and in Pennsylvania, United States, substantially completed their decommissioning efforts  and met the criteria for assets held for sale. Because the carrying value of the sites did not exceed their estimated fair value, no additional impairment was recorded. As of June 30, 2015, the sites held for sale represent $1.7 million of assets reported under "Property, plant and equipment" and $0.5 million of liabilities, reported under "Other accrued liabilities".

All Plans
 
For the Six Months Ended June 30, 2014
 
For the Six Months Ended June 30, 2015
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
 
 
 
 
 
 
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
 
 
 
 
 
 
 
 
Accelerated
   depreciation
 
 
$
20,852

 
$
826

 
$

 
$
21,678

 
$
432

 
$

 
$

 
$
432

Inventory loss
 
667

 
11,048

 

 
11,715

 
(61
)
 
947

 

 
886

Fixed asset
   write-offs
     and other
 
3,909

 
131

 

 
4,040

 
1,655

 
973

 

 
2,628

Recorded in Research and Development
 
 
 
 
 
 
 
 
 
 
Accelerated
   depreciation
 
 

 

 

 

 

 

 
940

 
940

Recorded in Selling and General Administrative
 
 
 
 
 
 
 
 
 
 
Other
 
78

 

 

 
78

 
400

 
295

 
790

 
1,485

Recorded in Rationalizations
 
 
 
 
 
 
 
 
 
 
Severance
  and related
    costs
 
418

 
(28
)
 

 
390

 
157

 
4,006

 
(130
)
 
4,033

Contract terminations
 
528

 

 

 
527

 
25

 
204

 

 
229

Total
 
$
26,452

 
$
11,977

 
$

 
$
38,428

 
$
2,608

 
$
6,425

 
$
1,600

 
$
10,633


2013 Industrial Materials Rationalization
On October 31, 2013, we announced a global initiative to reduce our Industrial Materials segment's cost base and improve our competitive position. As part of this initiative, we ceased production at our two highest cost graphite electrode plants, located in Brazil and South Africa, as well as a machine shop in Russia. Our graphite electrode capacity was reduced by approximately 60,000 metric tons as a result of these actions. In parallel, we adopted measures for reductions in overhead and related corporate operations. These actions and measures reduced global headcount by approximately 600 people, or approximately 20 percent of our global workforce. These actions were substantially completed during the first half of 2014.

2013 Engineered Solutions Rationalization
In order to optimize our Engineered Solutions platform and improve our cost structure, we also initiated actions to centralize certain operations and reduce overhead in our Engineered Solutions segment. These actions reduced global headcount by approximately 40 people and were substantially completed during 2014.



Total 2013 Rationalization Initiatives Impact to Financial Results
Charges incurred related to the 2013 rationalization initiatives for the six months ended June 30, 2014 and June 30, 2015 are as follows:
2013 Plans
 
For the Three Months Ended June 30, 2014
 
For the Three Months Ended June 30, 2015
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
 
 
 
 
 
 
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
 
 
 
 
 
 
 
 
Accelerated
   depreciation
 
 
$
3,832

 
$
413

 
$

 
$
4,245

 
$

 
$

 
$

 
$

Inventory loss
 
(148
)
 
496

 

 
348

 

 

 

 

Fixed asset
   write-offs
     and other
 
4,403

 
131

 

 
4,534

 
413

 
249

 

 
662

Recorded in Selling and General Administrative
 
 
 
 
 
 
 
 
 
 
Other
 
52

 

 

 
52

 

 

 

 

Recorded in Rationalizations
 
 
 
 
 
 
 
 
 
 
Severance
  and related
    costs
 
304

 

 

 
304

 
10

 
146

 

 
156

Contract terminations
 
528

 

 

 
528

 

 

 

 

Total
 
$
8,971

 
$
1,040

 
$

 
$
10,011

 
$
423

 
$
395

 
$

 
$
818


2013 Plans
 
For the Six Months Ended June 30, 2014
 
For the Six Months Ended June 30, 2015
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
 
 
 
 
 
 
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
 
 
 
 
 
 
 
 
Accelerated
   depreciation
 
 
$
20,852

 
$
826

 
$

 
$
21,678

 
$
432

 
$

 
$

 
$
432

Inventory loss
 
667

 
486

 

 
1,153

 
(61
)
 

 

 
(61
)
Fixed asset
   write-offs
     and other
 
3,909

 
131

 

 
4,040

 
1,655

 
258

 

 
1,913

Recorded in Selling and General Administrative
 
 
 
 
 
 
 
 
 
 
Other
 
78

 

 

 
78

 

 

 

 

Recorded in Rationalizations
 
 
 
 
 
 
 
 
 
 
Severance
  and related
    costs
 
418

 
(28
)
 

 
390

 
97

 
146

 

 
243

Contract terminations
 
528

 

 

 
528

 
25

 

 

 
25

Total
 
$
26,452

 
$
1,415

 
$

 
$
27,867

 
$
2,148

 
$
404

 
$

 
$
2,552




The following table represents the roll-forward of the liability incurred for employee termination benefits and contract termination costs incurred in connection with the the rationalization initiatives described above. This liability is recorded as a current liability on the Consolidated Balance Sheets.
2013 Plans
 
(Dollars in thousands)
Balance as of December 31, 2013
$
18,421

       Charges incurred
613

       Change in estimates
153

       Payments and settlements
(16,494
)
       Effect of change in currency exchange rates
(1,658
)
Balance as of December 31, 2014
1,035

Charges incurred
41

Change in estimates
229

Payments and settlements
(1,132
)
Effect of change in currency exchange rates
(91
)
Balance as of June 30, 2015
$
82



2014 Engineered Solutions Rationalization
    
On July 29, 2014, we announced additional rationalization initiatives to increase profitability, reduce cost and improve global competitiveness in our Engineered Solutions segment. During the second quarter of 2014, worldwide pricing of our isomolded graphite products ("isomolded") within our Advanced Graphite Material ("AGM") product group, as well as our expectation of future pricing, significantly eroded, driven by significant over-capacity and recent competitor responses. In addition, solar product demand continued to erode, with polysilicon, silicon and silicon wafer production migrating to China. New competitors servicing this industry commenced production in China at pricing levels making the market now unprofitable. As a result of these conditions, the Company decided to cease isomolded production and pursue alternative supply chain relationships in our isomolded product line.
As a result of the above, we tested our long-lived assets used to produce advanced graphite materials for recovery, based on undiscounted cash flows from the use and eventual disposition of these assets. The carrying value of the assets exceeded these undiscounted cash flow and, accordingly, we estimated the fair-value of these long-lived assets based on a market participant view. This resulted in an impairment charge totaling 121.6 million during 2014, and included the impairment of certain acquired customer relationship and technology intangible assets.
Charges incurred related to the 2014 Engineered Solutions rationalization initiatives in 2015 are as follows:
2014
Engineered Solutions Rationalization
 
For the Three Months Ended June 30, 2014
 
 
For the Three Months Ended June 30, 2015
 
 
 
Engineered Solutions Segment
 
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
 
Inventory loss
 
10,562

 
 
109

 
Fixed asset
   write-offs
     and other
 

 
 
360

 
Recorded in Rationalizations
 
 
 
Severance
  and related
    costs
 

 
 
(733
)
 
Total
 
$
10,562

 
 
$
(264
)
 
2014
Engineered Solutions Rationalization
 
For the Six Months Ended June 30, 2014
 
 
For the Six Months Ended June 30, 2015
 
 
 
Engineered Solutions Segment
 
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
 
Inventory loss
 
$
10,562

 
 
$
543

 
Fixed asset
   write-offs
     and other
 

 
 
358

 
Recorded in Rationalizations
 
 
 
Severance
  and related
    costs
 

 
 
(749
)
 
Contract terminations
 

 
 
50

 
Total
 
$
10,562

 
 
$
202

 

The following table represents the roll-forward of the liability incurred for employee termination benefits and contract termination costs incurred in connection with the 2014 Engineered Solutions rationalization initiatives described above. This liability is recorded as a current liability on the Consolidated Balance Sheets.
2014 Engineered Solutions Plan
 
(Dollars in thousands)
Balance as of December 31, 2013
$

Charges incurred
2,611

Change in estimates
(40
)
Payments and settlements
(916
)
Balance as of December 31, 2014
1,655

Charges incurred
50

Change in estimates
(749
)
Payments and settlements
(780
)
Balance as of June 30, 2015
$
176



2014 Corporate and Research & Development Rationalization
During the third quarter of 2014, we announced the conclusion of another phase of our on-going company-wide cost savings assessment. This resulted in changes to the Company’s operating and management structure in order to streamline, simplify and decentralize the organization. These actions are designed to reduce costs by a combination of reduced contractor costs, attrition, early retirements and layoffs. Additionally, the Company downsized its corporate functions by approximately 25 percent, relocated to a smaller, more cost effective corporate headquarters and established a new Technology and Innovation Center. The 2014 Corporate and Research and Development rationalization plan will result in approximately $20 million of charges consisting of severance, accelerated depreciation and other related costs, of which approximately $14 million have been incurred through June 30, 2015. Approximately $12 million of these costs will be cash outlays, the majority of which are expected to be disbursed in 2015.
Charges incurred related to the 2014 Corporate and Research & Development rationalization initiatives for 2015 are as follows:
2014 Corporate, Research and Development Rationalization
 
For the Three Months Ended June 30, 2015
 
For the Six Months Ended June 30, 2015
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
 
 
 
 
 
 
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
 
 
 
 
 
 
 
 
Fixed asset
   write-offs
     and other
 

 
1

 

 
$
1

 

 
1

 

 
1

Recorded in Research and Development
 
 
 
 
 
 
 
 
 
 
Accelerated
   depreciation
 
 

 

 
319

 
$
319

 

 

 
940

 
940

Recorded in Selling and General Administrative
 
 
 
 
 
 
 
 
 
 
Other
 
400

 

 
(276
)
 
$
124

 
400

 

 
790

 
1,190

Recorded in Rationalizations
 
 
 
 
 
 
 
 
 
 
Severance
  and related
    costs
 
94

 
8

 
(130
)
 
$
(28
)
 
60

 
8

 
(130
)
 
(62
)
Total
 
$
494

 
$
9

 
$
(87
)
 
$
416

 
$
460

 
$
9

 
$
1,600

 
$
2,069



The following table represents the roll-forward of the liability incurred for employee termination benefits and contract termination costs incurred in connection with the 2014 Corporate and Research & Development rationalization initiatives described above. This liability is recorded as a current liability on the Consolidated Balance Sheets.
2014 Corporate and R&D Plan
 
(Dollars in thousands)
Balance as of December 31, 2013
$

Charges incurred
8,159

Change in estimates
21

Payments and settlements
(1,155
)
Effect of change in currency exchange rates
(152
)
Balance as of December 31, 2014
6,873

Charges incurred
(34
)
Change in estimates
(28
)
Payments and settlements
(4,199
)
Effect of change in currency exchange rates
(5
)
Balance as of June 30, 2015
$
2,607


2015 Advanced Graphite Materials Rationalization
On March 2, 2015, GrafTech announced plans to further optimize the production platform for its advanced graphite materials business. These actions included the closure of our Notre Dame, France facility and further reductions in force in our Columbia, Tennessee facility and other locations totaling approximately 85 people. The 2015 Advanced Graphite Materials rationalization plan will result in approximately $10 million of charges consisting of severance, inventory losses and other related costs. Approximately $8 million of these costs will be cash outlays, the majority of which are expected to be disbursed in 2015.
Charges incurred related to the 2015 Advanced Graphite Materials rationalization initiative for the three and six months ended June 30, 2015 are as follows:
2015 Advanced Graphite Materials Rationalization
 
For the Three Months Ended June 30, 2015
 
For the Six Months Ended June 30, 2015
 
 
 
Engineered Solutions Segment
 
 
 
 
 
 
 
Recorded in Cost of Sales
 
 
Inventory loss
 
35

 
404

 
Fixed asset
   write-offs
     and other
 
461

 
356

 
Recorded in Selling and General Administrative
 
 
Other
 
292

 
295

 
Recorded in Rationalizations
 
 
Severance
  and related
    costs
 
2,220

 
4,601

 
Contract terminations
 
154

 
154

 
Total
 
$
3,162

 
$
5,810

 
The following table represents the roll-forward of the liability incurred for employee termination benefits and contract termination costs incurred in connection with the 2015 Advanced Graphite Materials rationalization initiative described above. This liability is recorded as a current liability on the Consolidated Balance Sheets.
2015 Advanced Graphite Materials Rationalization
 
(Dollars in thousands)
Balance as of December 31, 2014
$

Charges incurred
4,834

Payments and settlements

(263
)
Effect of change in currency exchange rates

(38
)
Balance as of June 30, 2015
$
4,533