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Facility Consolidation and Other Costs
12 Months Ended
Dec. 31, 2018
Restructuring and Related Activities [Abstract]  
Facility Consolidation and Other Costs
RESTRUCTURING PLANS

2016 Restructuring and Cost Savings Plan ("2016 Plan")

During the second quarter of 2016, the Company initiated a restructuring and cost savings plan ("2016 Plan") to improve efficiencies and reduce fixed costs. As a part of this plan, four Latin American facilities will be closed. Most of the production from these facilities was transferred to other facilities. As of December 31, 2018, manufacturing operations had ceased at all four of these manufacturing facilities. The total 2016 Plan costs were $31.6 million, comprised of $13.2 million in employee termination costs, $1.4 million in fixed asset related costs, and $17.0 million in other costs which primarily represent the cost to move and re-install equipment. These amounts exclude any potential gain to be recognized on the sale of property.

The 2016 Plan costs are as follows:

(in millions)
 
Latin America Packaging
 
Rest of World Packaging
 
Total
   2016 net expense accrued
 
$
20.5

 
$
1.1

 
$
21.6

   2017 net expense accrued
 
8.0

 
0.2

 
8.2

   2018 net expense accrued
 
2.0

 
(0.2
)
 
1.8

Expense incurred to date
 
30.5

 
1.1

 
31.6

   Estimated future expense
 

 

 

Estimated costs of program
 
$
30.5

 
$
1.1

 
$
31.6


An analysis of the 2016 program accruals follows:
(in millions)
 
Employee Costs
 
Fixed Asset Related
 
Other Costs
 
Total Restructuring Costs
Reserve balance at December 31, 2017
 
$
1.1

 
$

 
$
4.4

 
$
5.5

Net expense accrued
 
(0.3
)
 

 
2.1

 
1.8

Utilization (cash payments or otherwise settled)
 
(0.6
)
 

 
(2.3
)
 
(2.9
)
Translation adjustments and other
 
(0.2
)
 

 
(0.7
)
 
(0.9
)
Reserve balance at December 31, 2018
 
$

 
$

 
$
3.5

 
$
3.5



Plant closings associated with the 2016 Plan are complete, with the last facility closing in the fourth quarter of 2017. Cash payments in 2018 and 2017 totaled $2.9 million and $15.4 million, respectively. The costs related to restructuring activities have been recorded on the consolidated statement of income as restructuring and other costs. The accruals related to restructuring activities have been recorded on the consolidated balance sheet primarily as other current liabilities.

2017 Restructuring and Cost Savings Plan ("2017 Plan")    

On June 30, 2017, the Company announced restructuring activities targeted to improve efficiency and profitability that further positions the Company for long-term success. As a part of this plan, the Company announced the intention to close four production facilities for which business will be relocated to existing facilities and the closure of an additional manufacturing facility for which business will not be relocated to optimize manufacturing capacity. In addition, the Company announced it will reduce administrative positions by approximately 500 positions and consolidate certain administrative offices and take other actions to improve the cost efficiency of a variety of administrative and operational processes.

The Company expects total 2017 Plan pre-tax restructuring costs of approximately $65 to $70 million, which includes $29 to $31 million in employee termination costs, $19 to $20 million in fixed asset related expenses, and $17 to $19 million in other restructuring project costs, including the movement and re-installation of equipment. Expenses in the twelve months ended December 31, 2018 were $19.3 million, which consisted primarily of employee termination costs and fixed asset write-downs of equipment.

The estimated 2017 Plan costs are as follows:
(in millions)
 
U.S. Packaging
 
Latin America Packaging
 
Rest of World Packaging
 
Corporate
 
Total
   2017 net expense accrued
 
$
13.4

 
$
20.7

 
$
1.5

 
$
3.5

 
$
39.1

   2018 net expense accrued
 
9.6

 
7.3

 
1.9

 
0.5

 
19.3

Expense incurred to date
 
23.0

 
28.0

 
3.4

 
4.0

 
58.4

   Estimated future expense
 
6.7

 
4.0

 
0.3

 
0.1

 
11.1

Estimated costs of program
 
$
29.7

 
$
32.0

 
$
3.7

 
$
4.1

 
$
69.5


An analysis of the 2017 Plan accruals follows:
(in millions)
 
Employee Costs
 
Fixed Asset Related
 
Other Costs
 
Total Restructuring Costs
Reserve balance at December 31, 2017
 
$
19.2

 
$

 
$
2.5

 
$
21.7

Net expense accrued
 
3.7

 
11.4

 
4.5

 
19.6

Utilization (cash payments or otherwise settled)
 
(13.6
)
 
(11.4
)
 
(2.5
)
 
(27.5
)
Accrual adjustment
 
(0.2
)
 

 
(0.1
)
 
(0.3
)
Translation adjustments and other
 
(2.2
)
 

 
(0.4
)
 
(2.6
)
Reserve balance at December 31, 2018
 
$
6.9

 
$

 
$
4.0

 
$
10.9



The 2017 Plan is expected to be completed by the end of 2020. Cash payments in the twelve months ended December 31, 2018 and 2017 were $17.4 million and $6.8 million, respectively. The costs related to restructuring activities have been recorded on the consolidated statement of income as restructuring and other costs. The accruals related to restructuring activities have primarily been recorded on the consolidated balance sheet as other current liabilities.