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Rationalizations and Impairments
9 Months Ended
Sep. 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 are as follows:
All Plans
 
For the Three Months Ended
September 30, 2014 (Predecessor)
 
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
 
(Dollars in thousands)
 
Recorded in Cost of Sales
 
 
 
   Accelerated depreciation
 
 
$
838

 
$
2,807

 
$

 
$
3,645

 
   Inventory loss
 
324

 
2,606

 

 
2,930

 
   Fixed asset write-offs and other
 
1,294

 
180

 

 
1,474

 
Recorded in Research and Development
 
 
 
   Accelerated Depreciation
 

 

 
89

 
89

 
Recorded in Selling and General Administrative
 
 
 
   Other
 
20

 

 

 
20

 
Recorded in Rationalizations
 
 
 
   Severance and related costs
 
4,643

 
3,102

 
2,870

 
10,615

 
   Contract terminations
 
82

 
146

 

 
228

 
Total
 
$
7,201

 
$
8,841

 
$
2,959

 
$
19,001

 
All Plans
 
For the Period July 1, 2015
Through August 14, 2015 (Predecessor)
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
 
 
 
 
 
   Accelerated depreciation
 
$

 
$

 
$

 
$

   Inventory loss
 
27

 
28

 

 
55

   Fixed asset write-offs and other
 
59

 
105

 

 
164

Recorded in Research and Development
 
 
 
 
 
   Accelerated Depreciation
 

 
461

 
164

 
625

Recorded in Selling and General Administrative
 
 
 
 
 
 
   Other
 

 

 

 

Recorded in Rationalizations
 
 
 
 
 
 
 
   Severance and related costs
 

 
282

 
(39
)
 
243

   Contract terminations
 

 

 

 

Total
 
$
86

 
$
876

 
$
125

 
$
1,087

All Plans
 
For the Period August 15, 2015
Through September 30, 2015 (Successor)
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
 
 
 
 
 
   Accelerated depreciation
 
$

 
$

 
$

 
$

   Inventory loss
 
15

 
132

 

 
147

   Fixed asset write-offs and other
 
15

 
351

 

 
366

Recorded in Research and Development
 
 
 
 
 
 
   Accelerated Depreciation
 

 

 

 

Recorded in Selling and General Administrative
 
 
 
 
 
 
   Other
 

 
201

 
10

 
211

Recorded in Rationalizations
 
 
 
 
 
 
 
   Severance and related costs
 
156

 
480

 

 
636

   Contract terminations
 

 

 

 

Total
 
$
186

 
$
1,164

 
$
10

 
$
1,360


During the second quarter of 2015, in connection with our rationalization initiatives, two sites, located in Salvador, Brazil and 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. Our Pennsylvania facility was sold in the third quarter of 2015 for a gain of $0.3 million. Additionally, during the third quarter of 2015, our facility in Meyerton, South Africa substantially completed their decommissioning efforts and met the criteria for assets held for sale. As of September 30, 2015, the sites held for sale represent $7.7 million of assets reported under "Property, plant and equipment" and $1.5 million of liabilities, reported under "Other accrued liabilities".
All Plans
 
For the Nine Months Ended
September 30, 2014 (Predecessor)
 
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
 
(Dollars in thousands)
 
Recorded in Cost of Sales
 
 
 
   Accelerated depreciation
 
$
21,690

 
$
3,633

 
$

 
$
25,323

 
   Inventory loss
 
991

 
13,654

 

 
14,645

 
   Fixed asset write-offs and other
 
5,203

 
310

 

 
5,513

 
Recorded in Research and Development
 
 
 
   Accelerated Depreciation
 

 

 
89

 
89

 
Recorded in Selling and General Administrative
 
 
 
   Other
 
98

 

 

 
98

 
Recorded in Rationalizations
 
 
 
   Severance and related costs
 
5,061

 
3,074

 
2,870

 
11,005

 
   Contract terminations
 
610

 
146

 

 
756

 
Total
 
$
33,653

 
$
20,817

 
$
2,959

 
$
57,429

 
All Plans
 
For the Period January 1
Through August 14, 2015 (Predecessor)
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$
432

 
$

 
$

 
$
432

   Inventory loss
 
(33
)
 
975

 

 
942

   Fixed asset write-offs and other
 
1,715

 
1,078

 

 
2,793

Recorded in Research and Development
 
 
   Accelerated Depreciation
 

 

 
940

 
940

Recorded in Selling and General Administrative
 
 
   Other
 
400

 
755

 
954

 
2,109

Recorded in Rationalizations
 
 
   Severance and related costs
 
157

 
4,288

 
(168
)
 
4,277

   Contract terminations
 
25

 
204

 

 
229

Total
 
$
2,696

 
$
7,300

 
$
1,726

 
$
11,722

All Plans
 
For the Period August 15
Through September 30, 2015 (Successor)
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$

 
$

 
$

 
$

   Inventory loss
 
15

 
132

 

 
147

   Fixed asset write-offs and other
 
15

 
351

 

 
366

Recorded in Research and Development
 
 
   Accelerated depreciation
 

 

 

 

Recorded in Selling and General Administrative
 
 
   Other
 

 
201

 
10

 
211

Recorded in Rationalizations
 
 
   Severance and related costs
 
156

 
480

 

 
636

   Contract terminations
 

 

 

 

Total
 
$
186

 
$
1,164

 
$
10

 
$
1,360


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 are as follows:
2013 Plans
 
For the Three Months Ended
September 30, 2014 (Predecessor)
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$
838

 
$

 
$

 
$
838

   Inventory loss
 
324

 

 

 
324

   Fixed asset write-offs and other
 
1,294

 
6

 

 
1,300

Recorded in Selling and General Administrative
 
 
   Other
 
20

 

 

 
20

Recorded in Rationalizations
 
 
   Severance and related costs
 
(52
)
 

 

 
(52
)
   Contract terminations
 
82

 

 

 
82

Total
 
$
2,506

 
$
6

 
$

 
$
2,512

2013 Plans
 
For the Period July 1, 2015
Through August 14, 2015 (Predecessor)
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$

 
$

 
$

 
$

   Inventory loss
 
27

 

 

 
27

   Fixed asset write-offs and other
 
59

 
12

 

 
71

Recorded in Selling and General Administrative
 
 
   Other
 

 

 

 

Recorded in Rationalizations
 
 
   Severance and related costs
 

 
10

 

 
10

   Contract terminations
 

 

 

 

Total
 
$
86

 
$
22

 
$

 
$
108

2013 Plans
 
For the Period August 15
Through September 30, 2015 (Successor)
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$

 
$

 
$

 
$

   Inventory loss
 
15

 

 

 
15

   Fixed asset write-offs and other
 
15

 

 

 
15

Recorded in Selling and General Administrative
 
 
   Other
 

 

 

 

Recorded in Rationalizations
 
 
   Severance and related costs
 
156

 

 

 
156

   Contract terminations
 

 

 

 

Total
 
$
186

 
$

 
$

 
$
186



2013 Plans
 
For the Nine Months Ended
September 30, 2014 (Predecessor)
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$
21,690

 
$
826

 
$

 
$
22,516

   Inventory loss
 
991

 
491

 

 
1,482

   Fixed asset write-offs and other
 
5,203

 
131

 

 
5,334

Recorded in Selling and General Administrative
 
 
   Other
 
99

 

 

 
99

Recorded in Rationalizations
 
 
   Severance and related costs
 
366

 
(28
)
 

 
338

   Contract terminations
 
609

 

 

 
609

Total
 
$
28,958

 
$
1,420

 
$

 
$
30,378

2013 Plans
 
For the Period January 1, 2015
Through August 14, 2015 (Predecessor)
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$
432

 
$

 
$

 
$
432

   Inventory loss
 
(33
)
 

 

 
(33
)
   Fixed asset write-offs and other
 
1,715

 
270

 

 
1,985

Recorded in Selling and General Administrative
 
 
   Other
 

 

 

 

Recorded in Rationalizations
 
 
   Severance and related costs
 
97

 
156

 

 
253

   Contract terminations
 
25

 

 

 
25

Total
 
$
2,236

 
$
426

 
$

 
$
2,662

2013 Plans
 
For the Period August 15, 2015
Through September 30, 2015 (Successor)
 
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$

 
$

 
$

 
$

   Inventory loss
 
15

 

 

 
15

   Fixed asset write-offs and other
 
15

 

 

 
15

Recorded in Selling and General Administrative
 
 
   Other
 

 

 

 

Recorded in Rationalizations
 
 
   Severance and related costs
 
156

 

 

 
156

   Contract terminations
 

 

 

 

Total
 
$
186

 
$

 
$

 
$
186




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 included in "Rationalizations" 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
193

Change in estimates
214

Payments and settlements
(1,057
)
Effect of change in currency exchange rates
(212
)
Balance as of September 30, 2015
$
173



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 are as follows:
 
 
Predecessor
 
Successor
 
2014 Engineered Solutions Rationalization
 
For the Three
Months Ended
September 30, 2014
 
For the Period July 1, 2015 Through August 14, 2015
 
For the Period
August 15, 2015
Through
September 30, 2015
 
 
 
Engineered Solutions Segment
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
 
   Accelerated depreciation
 
$
2,802

 
$

 
$

 
   Inventory loss
 
2,606

 
28

 
132

 
   Fixed asset write-offs
   and other
 
174

 
15

 
(267
)
 
Recorded in Rationalizations
 

 
   Severance and related costs
 
2,537

 
36

 

 
   Contract terminations
 
74

 

 

 
Total
 
$
8,193

 
$
79

 
$
(135
)
 
 
 
Predecessor
 
Successor
2014
Engineered Solutions Rationalization
 
For the Nine
Months Ended September 30, 2014
 
For the Period January 1, 2015 Through
August 14, 2015
 
For the Period
August 15, 2015
Through
September 30, 2015
 
 
Engineered Solutions Segment
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$
2,802

 
$

 
$

   Inventory loss
 
13,168

 
571

 
132

   Fixed asset write-offs
and other
 
174

 
372

 
(267
)
Recorded in Rationalizations
 
 
   Severance and related costs
 
2,537

 
(713
)
 

   Contract terminations
 
74

 
50

 

Total
 
$
18,755

 
$
280

 
$
(135
)
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 included in "Rationalizations" 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
(716
)
Payments and settlements
(979
)
Balance as of September 30, 2015
$
10



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 September 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 are as follows:
2014 Corporate, Research and Development Plan
 
For the Three Months Ended
September 30, 2014 (Predecessor)
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$

 
$
5

 
$

 
$
5

   Fixed asset write-offs
and other
 

 

 

 

Recorded in Research and Development
 
 
   Accelerated depreciation
 

 

 
89

 
89

Recorded in Selling and General Administrative
 
 
   Other
 

 

 

 

Recorded in Rationalizations
 
 
   Severance and related costs
 
4,695

 
565

 
2,870

 
8,130

   Contract terminations
 

 
74

 

 
74

Total
 
$
4,695

 
$
644

 
$
2,959

 
$
8,298

2014 Corporate, Research and Development Plan
 
For the Period July 1, 2015
Through August 14, 2015 (Predecessor)
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$

 
$

 
$

 
$

   Fixed asset write-offs
and other
 

 

 

 

Recorded in Research and Development
 
 
   Accelerated depreciation
 

 

 

 

Recorded in Selling and General Administrative
 
 
   Other
 

 

 
164

 
164

Recorded in Rationalizations
 
 
   Severance and related costs
 

 

 
(39
)
 
(39
)
   Contract terminations
 

 

 

 

Total
 
$

 
$

 
$
125

 
$
125

2014 Corporate, Research and Development Plan
 
For the Period August 15, 2015 Through September 30, 2015 (Successor)
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$

 
$

 
$

 
$

   Fixed asset write-offs
and other
 

 

 

 

Recorded in Research and Development
 
 
   Accelerated depreciation
 

 

 

 

Recorded in Selling and General Administrative
 
 
   Other
 

 

 
10

 
10

Recorded in Rationalizations
 
 
   Severance and related costs
 

 

 

 

   Contract terminations
 

 

 

 

Total
 
$

 
$

 
$
10

 
$
10


2014 Corporate, Research and Development Plan
 
For the Nine Months Ended
September 30, 2014 (Predecessor)
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$

 
$
5

 
$

 
$
5

   Fixed asset write-offs and other
 

 

 

 

Recorded in Research and Development
 
 
   Accelerated depreciation
 

 

 
89

 
89

Recorded in Selling and General Administrative
 
 
   Other
 

 

 

 

Recorded in Rationalizations
 
 
   Severance and related costs
 
4,695

 
565

 
2,870

 
8,130

   Contract terminations
 

 
74

 

 
74

Total
 
$
4,695

 
$
644

 
$
2,959

 
$
8,298

2014 Corporate, Research and Development Plan
 
For the Period January 1
Through August 14, 2015 (Predecessor)
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$

 
$

 
$

 
$

   Fixed asset write-offs and other
 

 
1

 

 
1

Recorded in Research and Development
 
 
   Accelerated depreciation
 

 

 
940

 
940

Recorded in Selling and General Administrative
 
 
   Other
 
400

 

 
954

 
1,354

Recorded in Rationalizations
 
 
   Severance and related costs
 
60

 
8

 
(168
)
 
(100
)
   Contract terminations
 

 

 

 

Total
 
$
460

 
$
9

 
$
1,726

 
$
2,195

2014 Corporate, Research and Development Plan
 
For the Period August 15
Through September 30, 2015 (Successor)
 
Industrial Materials Segment
 
Engineered Solutions Segment
 
Corp, R&D and Other
 
Total
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
   Accelerated depreciation
 
$

 
$

 
$

 
$

   Fixed asset write-offs and other
 

 

 

 

Recorded in Research and Development
 
 
   Accelerated depreciation
 

 

 

 

Recorded in Selling and General Administrative
 
 
   Other
 

 

 
10

 
10

Recorded in Rationalizations
 
 
   Severance and related costs
 

 

 

 

   Contract terminations
 

 

 

 

Total
 
$

 
$

 
$
10

 
$
10



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 included in "Rationalizations" 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
(33
)
Change in estimates
(67
)
Payments and settlements
(5,046
)
Effect of change in currency exchange rates
(121
)
Balance as of September 30, 2015
$
1,606


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 are as follows:
 
 
Predecessor
 
Successor
2015 Advanced Graphite Materials Rationalization
 
For the Period July 1 Through
August 14, 2015
 
For the Period January 1
Through
August 14, 2015
 
For the Period August 15
Through
September 30, 2015
 
 
Engineered Solutions Segment
 
 
(Dollars in thousands)
Recorded in Cost of Sales
 
 
 
   Inventory loss
 

 
404

 

   Fixed asset write-offs and other
 
78

 
434

 
618

Recorded in Selling and General Administrative
 
 
 
   Other
 
461

 
755

 
201

Recorded in Rationalizations
 
 
 
   Severance and related costs
 
236

 
4,838

 
480

   Contract terminations
 

 
154

 

Total
 
$
775

 
$
6,585

 
$
1,299

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 included in "Rationalizations" on the Consolidated Balance Sheets.
2015 Advanced Graphite Materials Rationalization
 
(Dollars in thousands)
Balance as of December 31, 2014
$

Charges incurred
5,543

Payments and settlements

(2,032
)
Effect of change in currency exchange rates

(38
)
Balance as of September 30, 2015
$
3,473