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Rationalizations and Impairments
3 Months Ended
Mar. 31, 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 months ended March 31, 2014 and 2015 are as follows:
All Plans
For the Three Months Ended March 31, 2014
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corporate, R&D and Other
 
Total
 
(Dollars in thousands)
Accelerated depreciation
    (recorded in Cost of sales)
$
17,020

 
$
413

 
$

 
$
17,433

Inventory loss (recorded in Cost
    of sales)
815

 
(10
)
 

 
805

Fixed asset write-offs and other(recorded in Cost of sales)
(494
)
 
 
 

 
(494
)
Other (recorded in Selling
    and administrative)
25

 

 

 
25

Severance and related costs
    (recorded in Rationalizations)
114

 
(28
)
 

 
86

Total
$
17,480

 
$
375

 
$

 
$
17,855

All Plans
For the Three Months Ended March 31, 2015
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corporate, R&D and Other
 
Total
 
(Dollars in thousands)
Accelerated depreciation
    (recorded in Cost of sales)
$
433

 
$

 
$

 
$
433

Inventory loss (recorded in Cost
    of sales)
(61
)
 
803

 

 
742

Fixed asset write-offs and other(recorded in Cost of sales)
1,243

 
(99
)
 

 
1,144

Accelerated depreciation
(recorded in Research
       and development)

 

 
621

 
621

Other (recorded in Selling
    and administrative)

 
3

 
1,066

 
1,069

Severance and related costs
    (recorded in Rationalizations)
53

 
2,366

 

 
2,419

Contract terminations
(recorded in Rationalizations)
25

 
50

 

 
75

Total
$
1,693

 
$
3,123

 
$
1,687

 
$
6,503


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 three months ended March 31, 2014 and March 31, 2015 are as follows:
2013 Plan
For the Three Months Ended March 31, 2014
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corporate, R&D and Other
 
Total
 
(Dollars in thousands)
Accelerated depreciation
    (recorded in Cost of sales)
$
17,020

 
$
413

 
$

 
$
17,433

Inventory loss (recorded in Cost
    of sales)
815

 
(10
)
 

 
805

Fixed asset write-offs and other(recorded in Cost of sales)
(494
)
 

 

 
(494
)
Other (recorded in Selling
    and administrative)
25

 

 

 
25

Severance and related costs
    (recorded in Rationalizations)
114

 
(28
)
 

 
86

Total
$
17,480

 
$
375

 
$

 
$
17,855


2013 Plan
For the Three Months Ended March 31, 2015
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corporate, R&D and Other
 
Total
 
(Dollars in thousands)
Accelerated depreciation
    (recorded in Cost of sales)
$
433

 
$

 
$

 
$
433

Inventory loss (recorded in Cost
    of sales)
(61
)
 

 

 
(61
)
Fixed asset write-offs and other(recorded in Cost of sales)
1,243

 
9

 

 
1,252

Severance and related costs
    (recorded in Rationalizations)
87

 

 

 
87

Contract terminations
(recorded in Rationalizations)
25

 

 

 
25

Total
$
1,727

 
$
9

 
$

 
$
1,736



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 2013 Consolidated Balance Sheet.
2013 Plan
 
(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

Change in estimates
112

Payments and settlements
(549
)
Effect of change in currency exchange rates
(108
)
Balance as of March 31, 2015
$
490



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.

Charges incurred related to the 2014 Engineered Solutions rationalization initiatives in 2015 are as follows:
2014 Engineered Solutions Plan
 
For the Three Months Ended March 31, 2015
 
 
(Dollars in thousands)
Inventory loss (recorded in Cost
    of sales)
 
434

Fixed asset write-offs and other(recorded in Cost of sales)
 
(3
)
Severance and related costs
    (recorded in Rationalizations)
 
(16
)
Contract terminations
(recorded in Rationalizations)
 
50

Total
 
$
465


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 Sheet.
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
(16
)
Payments and settlements
(434
)
Balance as of March 31, 2015
$
1,255



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. 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 and R&D Plan
For the Three Months Ended March 31, 2015
 
Industrial Materials Segment
 
Corporate, R&D and Other
 
(Dollars in thousands)
 
(Dollars in thousands)
Accelerated depreciation
(recorded in Research
and development)
$

 
$
621

Other (recorded in Selling
    and administrative)

 
1,066

Severance and related costs
    (recorded in Rationalizations)
(34
)
 

Total
$
(34
)
 
$
1,687


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 Sheet.
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
(2
)
Change in estimates
(34
)
Payments and settlements
(2,231
)
Effect of change in currency exchange rates
(48
)
Balance as of March 31, 2015
$
4,558


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 months ended March 31, 2015 are as follows:
2015 Advanced Graphite Materials Rationalization
For the Three
 Months Ended
March 31, 2015
 
(Dollars in thousands)
Inventory loss (recorded in Cost of sales)
$
369

Fixed asset write-offs and other(recorded in Cost of sales)
(105
)
Other (recorded in Selling and administrative)
3

Severance and related costs (recorded in Rationalizations)
2,382

Total
$
2,649


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 Sheet.
2015 Advanced Graphite Materials Rationalization
 
(Dollars in thousands)
Balance as of December 31, 2014
$

Charges incurred
2,382

Payments and settlements

(36
)
Effect of change in currency exchange rates

(17
)
Balance as of March 31, 2015
$
2,329