Federal-Mogul Corporation Business report FY2009

Business Highlights

Financial Overview

(in million dollars)
  FY2008 FY2007 Rate of
change (%)
Factors
Sales 5,330 6,866 (22.4) -
Net Income (45) (468) - -
Powertrain Energy(PTE)
Sales 1,413 2,090 (32.4) -PTE generates over 80% of its revenue outside the United States and the resulting currency movements decreased reported sales by $137 million.

-Sales volumes decreased by $504 million due to OE production volume declines in all regions, slightly offset by market share gains and new program launches in all regions.

-Price downs associated with customer contractual agreements reduced sales by $36 million, including the impact of material price escalators whereby, through prior arrangements with certain customers, the Company transfers all, or part, of the changes in material costs to its customers.
Powertrain Sealing and Bearings(PTSB)
Sales 819 1,154 (29.0) -PTSB generates approximately 70% of its revenue outside the United States and the resulting currency movements decreased reported sales by $56 million.

-Sales volumes decreased by $292 million due to OE production volume declines in all regions, slightly offset by market share gains and new program launches in all regions.
-Customer pricing increased sales by $13 million.
Vehicle Safety and Protection (VSP)
Sales 772 985 (21.6) -VSP generates over 70% of its revenue outside the United States and the resulting currency movements decreased reported sales by $44 million.

-Sales volumes fell by $168 million due to lower OE production in all regions, slightly offset by market share gains and new program launches in all regions.
Global Aftermarket
Sales 2,326 2,637 (11.8) -The change was caused by decreased sales volumes in all regions totaling $290 million due to a combination of factors including the economic recession reducing consumer spending and the frailty of financial markets in Eastern Europe and South America, partially offset by customer price increases of $47 million. Unfavorable foreign currency movements were $68 million.

Contracts

-The Company announced to provide a wide range of power-cylinder, sealing, bearing and heat insulation components for the award-winning Ward's engines. The engines that feature
Federal-Mogul products are:

-Audi A4 2.0L TFSI Turbocharged DOHC I-4
-Audi S4 3.0L TFSI Supercharged DOHC V-6
-BMW 335d 3.0L DOHC I-6 Turbodiesel
-Ford Fusion Hybrid 2.5L DOHC I-4 Hybrid
-Chevrolet Equinox 2.4L Ecotec DOHC I-4
-Hyundai Genesis 4.6L Tau DOHC V-8
-Subaru Legacy 2.5 GT 2.5L Turbocharged DOHC H-4;
-Toyota Prius 1.8L DOHC I-4 Hybrid;
-Volkswagen Jetta Sport Wagen TDI 2.0L SOHC I-4 Turbodiesel
(From a press release on January 13, 2010)

Joint-Ventures

-In Oct. 2009, the Company and Russian heavy-duty truck manufacturer KAMAZ have established a 50/50 joint venture, called Federal-Mogul Naberezhnye Chelny, in Tatarstan, Russia and started the production. The new facility supplies engine parts such as aluminum diesel pistons. The next phase, anticipated to start in 2010, will extend the JV's product range to provide components compliant with Euro 4 emissions regulations. (From a press release on October 6, 2009)

R&D

R&D Expenditure

(in million dollars)
  FY2009 FY2008 FY2007
Overall 140 173 178

R&D Facilities

(As of Dec. 31, 2009)

  North
America
Europe Rest of
World
Technical centers 9 7 2

US: Plymouth, Michigan; Skokie, Illinois; Ann Arbor, Michigan; Exton, Pennsylvania; and Toledo, Ohio.
Internationally: Burscheid, Germany; Nuremberg, Germany; Wiesbaden, Germany; Bad Camberg, Germany; Chapel, United Kingdom; Crepy, France; Yokohama, Japan.

-The newest technical center in Shanghai, China is expected to open during the second quarter of 2009.

Product Development

Liquid Elastomer Molding gaskets
-In Jan. 2009, the Company developed Liquid Elastomer Molding (LEM(TM)) gaskets in use for fuel cell stacks. Each LEM gasket can be 0.3-0.5 mm thick, whereas the conventional molded gasket measures at least double that. This technology helps reduce the size and weight of each fuel cell stack. (From a press release on July 1, 2009)

Eco Friendly acoustical padding QuietShield GRN
-In Jan. 2009, the Company developed an eco-friendly acoustical padding QuietShield(R) GRN(Green Non-woven). QuietShield GRN is made from recycled waste packaging and by-product materials normally discarded at a vehicle manufacturing plant, including cardboard, carpet fibers, recycled yarns and fabrics. The product's first application was in the 2010 Buick LaCrosse, a luxury sedan by GM. It is used in the LaCrosse's headliner to reduce noise in the passenger compartment. QuietShield represents a lower cost solution to provide acoustical padding versus traditional products. (From a press release on Jan 10, 2009)

 

Investment Activities

Capital Expenditures

(in million dollars)
  FY2009 FY2008 FY2007
Powertrain Energy 76 140 149
Powertrain Sealing and Bearings 44 70 69
Vehicle Safety and Protection 38 71 62
Global Aftermarket
2 4 6
Corporate 16 35 24
Total 176 320 310