Johnson Controls Business Report FY2006
Business Highlights
in million dollars | FY2006 | FY2005 | Rate of change (%) | Factors |
Overall |
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Sales | 32,235 | 27,479 | 17.3 |
-In fiscal year 2006, the Company
recorded record net sales and record net income. |
Operating income | 1,282 | 1,066 | 20.3 | -The
increase in operating income was primarily due to the impact
of the York and Delphi acquisitions and organic growth in the
power solutions segment, partially offset by increased raw material
costs, including lead and petroleum-based products, lower North
American automobile production and unfavorable foreign currency
translation (approximately $25 million). - Operating income was also favorably impacted on a net basis in fiscal year 2006 by legal and customer contract settlements which were partially offset by York integration costs. -Excluding the unfavorable effects of foreign currency translation, operating income increased 23% as compared to the prior year. |
Automotive experience - North America |
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Sales | 8,041 | 8,499 | (5.4) | -North American net sales decreased slightly as higher volumes with DaimlerChrysler AG and Hyundai Motor Co. were more than offset by volume reductions with Ford Motor Co., General Motors Corporation and Nissan Motor Co. and an unfavorable mix of production from light trucks to passenger cars. |
Operating income | 145 | 350 | (58.6) | -Operating
income (excluding $75 million of restructuring costs) decreased
59% from the prior year (excluding $12 million of restructuring
costs). -Unfavorable vehicle volume and sales mix decreased operating income by $139 million as compared to the prior year. -Cost reduction programs, purchasing savings and other operational efficiencies contributed approximately $253 million in operating improvements. -Operations were unfavorably impacted by customer vehicle program adjustments ($133 million), tooling and launch costs ($68 million), higher labor costs ($48 million) and fuel cost increases ($47 million). -Selling, General and Administrative (SG&A) expenses increased primarily due to the timing of customer engineering recoveries ($18 million), employee benefit related expenses ($12 million) and plant closure costs related to a customer closure of an assembly plant to which the Company supplied interior products ($8 million), partially offset by administrative efficiencies and cost reduction programs. |
Automotive experience - Europe |
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Sales | 8,774 | 8,935 | (1.8) | -European net sales declined slightly as higher volumes across all major customer platforms were more than offset by the unfavorable impact of foreign currency translation (approximately $300 million). |
Operating income | 383 | 252 | 52.0 | -Operating
income (excluding $53 million of restructuring costs) increased
52% from the prior year (excluding $130 million of restructuring
costs). -Cost reduction programs, purchasing savings and other operational efficiencies contributed approximately $134 million in savings as compared to the prior period. -SG&A expenses increased $21 million, primarily due to information technology infrastructure expenses ($16 million) and net engineering expenses ($5 million). |
Automotive experience - Asia |
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Sales | 1,459 | 1,399 | 4.3 | -Asian net sales increased primarily due to higher volumes with Honda Motor Co. in Japan, partially offset by volume reductions with Nissan Motor Co. in Japan, seating and interiors businesses in Korea and the unfavorable impact of foreign currency translation (approximately $30 million). |
Operating income | (28) | 30 | (193.3) | -Asia
reported an operating loss in fiscal year 2006, primarily due
to lower volumes and product mix, start-up and engineering costs
associated with new programs within Japan, Korea and Malaysia
and unfavorable material costs. -Restructuring costs were $1 million in fiscal year 2006 compared to none in fiscal year 2005. |
Power solutions |
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Sales | 3,716 | 2,928 | 26.9 | -The
increase in net sales was due to substantially higher unit shipments,
primarily from the Delphi battery business acquisition, and
the favorable impact of higher lead costs on pricing, partially
offset by the unfavorable impact of foreign currency translation
(approximately $40 million). - Unit sales increased 22% in North America from new account growth in the aftermarket and increased sales to General Motors Corporation related to the Delphi battery business acquisition, 17% in Europe from strong aftermarket demand and 114% in Asia from increased market share. |
Operating income | 443 | 349 | 26.9 | -The increase in operating income was primarily due to the higher sales volumes and a favorable legal settlement associated with the recovery of previously incurred environmental costs ($33 million), partially offset by unfavorable commodity costs, primarily lead ($72 million). |
Contracts
-In April 2006, the Company announced that it has been selected
by General Motors to supply the seating system and other interior
components for the 2007 Saturn Outlook. This includes the "Smart
Slide" second-row seat feature. The "Smart Slide"
seating feature that enables quick, easy movement of the second-row
seats to provide access to the third row of the vehicle. Through
an array of pivot points, the second-row seat cushion flips up,
while the seat back slides forward toward the front seats.
-In August 2006, Johnson Controls-Saft Advanced Power Solutions
(JCS) has been awarded a 24-month contract to develop advanced,
lithium-ion (Li-Ion) batteries for hybrid-electric vehicles (HEVs)
by the United States Advanced Battery Consortium (USABC). In the
project, 50% financed by USABC, engineers and scientists at JCS
will enhance lithium-ion battery technology for near-future HEVs.
They will focus on accelerating Li- Ion technology development by
improving battery power in low temperatures, and creating solutions
that reduce battery system costs.
-In September 2006, Johnson Controls- Saft Advanced Power Solutions
(JCS) announced that the company has signed a letter of intent (LOI)
with a major vehicle manufacturer to supply lithium-ion (Li-Ion)
batteries. The LOI is for the development phase, which is expected
to lead to volume production for a later date.
-In 2007 the Company will launch major
new interior programs in every geographic market as a result of
the precedent years contract.
North America
-The Company begin delivery of seats, overhead systems, instrument
panels and door systems for the new Toyota Tundra. The Company will
provide seating, electronics, door panels, overhead systems and
the instrument cluster for the Saturn Outlook crossover vehicle.
These programs are in addition to more than a dozen other launches
during the year.
Europe
-In Europe, launches include seating, overhead systems and trim
for the Volvo C30, and seating, overhead systems and door systems
for the Kia CEED. The Company has also been awarded future business
with European automakers where, historically, it had lower than
average market shares.
Asia
-Major 2007 launches in China include seating, overhead systems
and instrument panels for the Mercedes E-Class, as well as for the
Volkswagen Bora.
Business Partnership
-In October 2005, the Company and Saft announced that the companies
have signed a memorandum of understanding to form a joint venture
for advanced technology batteries to accelerate their participation
in the hybrid vehicle market. The joint venture will develop, manufacture
and sell nickel metal hydride and lithium ion batteries for hybrid
electric vehicles (HEVs) and electric vehicles globally. The companies
expect the joint venture agreement to be finalized in early 2006
and will commence joint sales and marketing activities immediately.
-In January 2005, the Company and Saft announced they launched their
new joint venture, to supply advanced-technology batteries for current-
and future-generation hybrid-electric vehicles (HEVs) and electric
vehicles (Evs). The new joint venture is involved worldwide in the
development, production and sale of nickel-metal-hydride and lithium-ion
batteries for HEVs and Evs. Saft has contributed licenses for its
nickel metal hydride and lithium-ion technologies, plus manufacturing
know-how, for a 49% stake in a new company, Johnson Controls-Saft
Advanced Power Solutions. Johnson Controls has contributed licenses
for its technologies, plus manufacturing know-how and will contribute
$40m in cash and assets, for a 51% stake. HEV and EV batteries for
military applications will remain outside the scope of the joint
venture.
Acquisitions
-On December 9, 2005, the Company completed its acquisition of York
International Corporation (York), a leading global provider of heating,
ventilating, air conditioning (HVAC) equipment and services.The
Company paid $56.50 for each outstanding share of York common stock.
The total cost of the acquisition, excluding cash acquired, was
approximately $3.1 billion, including the assumption of $563 million
of debt, change in control payments and direct costs of the transaction.
-Also in fiscal year 2006, the Company completed six additional
acquisitions for a combined purchase price of $111 million, including
the assumption of debt, none of which were material to the Company窶冱
consolidated financial statements. In connection with these acquisitions,
the Company recorded goodwill of $57 million.
>>>Previous
Acquisitions
Joint-Ventures
-In February 2006, the Company signed a contract with Dongfeng Electronic
Technology Co., Ltd. (DETC) to set up a joint venture, Shanghai
Johnson Controls Automotive Electronics Co., Ltd.. The joint company
is capitalized at 5 million dollars, and 50.01% of its capital is
invested by Dongfeng Electronic Technology and 49.99 % by Johnson
Controls. The new company produces electronic components for automobiles,
including instrument meters for passenger cars, information displays
and body controllers.
-In December 2006, the Company announced a new joint venture with
Chery, one of the largest independents, to provide interior systems
starting in 2008. The Company has been a key supplier to Chinese
automakers like BAIC, SAIC and FAW for more than a decade. It operate
12 manufacturing plants to support its customers there.
Divestitures
-In January 2006, Gill Industries announced it has signed a letter
of intent to purchase the Eansa plant near Mexico City from Johnson
Controls. The Mexico plant will add processes, wire and tube bending,
and products such as seat frames and tracks. Terms were not disclosed
in the sale, which is expected to be completed by Jan. 31.
Restructuring
- As part of its continuing efforts to reduce costs and improve
the efficiency of its global operations, the Company committed to
a restructuring plan (2006 Plan) in the third quarter of fiscal
year 2006 and recorded a $197 million restructuring charge. The
2006 Plan, which primarily includes workforce reductions and plant
consolidations in the automotive experience and building efficiency
businesses, is expected to be substantially completed by the end
of the third quarter of fiscal year 2007.
- The automotive experience business related restructuring is focused
on improving the profitability associated with the manufacturing
and supply of instrument panels, headliners and other interior components
in North America and increasing the efficiency of seating component
operations in Europe.
- During the fourth quarter of fiscal year 2006, automotive experience
窶 North America recorded an additional $8 million for employee
severance and termination benefits. The Company expects to incur
other related and ancillary costs associated with some of these
restructuring activities in future periods. These costs are not
expected to be material and will be expensed as incurred.
-The 2006 Plan includes workforce reductions of approximately 4,700
employees (2,200 for automotive experience 窶 North America,
1,400 for automotive experience 窶 Europe, 200 for building
efficiency 窶 North America, 600 for building efficiency 窶
Europe, 280 for building efficiency 窶 rest of world and 20
for power solutions). Restructuring charges associated with employee
severance and termination benefits will be paid over the severance
period granted to each employee and on a lump sum basis when required
in accordance with individual severance agreements. As of September
30, 2006, approximately 350 employees have been separated from the
Company. In addition, the 2006 Plan includes 15 plant closures (10
in automotive experience 窶 North America, 3 in automotive
experience 窶 Europe, 1 in
building efficiency 窶 Europe and 1 in building efficiency
窶 rest of world). The restructuring charge for the impairment
of the long-lived assets associated with the plant closures was
determined using an undiscounted cash flow analysis.
-The Company recorded the restructuring charge as a result of management窶冱
ongoing review of the Company窶冱 cost structure, the sharp
increase in commodity costs, and the current economic difficulties
facing some of its most significant customers. Company management
is continually analyzing its businesses for opportunities to consolidate
current operations and to locate its facilities in low cost countries
in close proximity to its customers. This ongoing
analysis includes the review of its manufacturing, engineering and
purchasing operations as well as its overall Company footprint.
Environmental Activities
-At the manufacturing facilities in 2006 the Company launched a
comprehensive energy services program focused on identifying opportunities
for energy improvement. The program includes a five-phase assessment
focused on the following areas: energy supply management, energy
asset management, utility bill management, energy information management,
and regulatory compliance and sustainability. In the program窶冱
first year, the Company audited five of our U.S.-based manufacturing
facilities. Best practices are being identified for global implementation
as the program moves into the regulatory compliance and sustainability
phase.
-Recycling and waste reduction are also critical components of the
internal environmental objectives. The Company is a leading company
in the development of a recycling process for automotive batteries,
making them the most recycled consumer product in the United States
窶 99 percent recycled versus 45 percent for aluminum cans
and 50 percent for paper. The Company is taking that expertise global
through a partnership with the National Development and Reform Commission
(NDRC) in the People窶冱 Republic of China, where the Company
is working together to develop an improved process for environmentally-friendly
recycling of automotive batteries.
-In Europe, the Company has developed processes for reusing glass-fiber
reinforced plastics from automotive instrument panels into air ducts
and mouldings for engine compartments, adding up to savings of approximately
400 tons per year of glass fiber reinforced plastics. Additionally,
natural products like coconut husk fibers are used in high-end car
seats resulting in economic and ecologic savings.
Outlook
Net Sales
-In fiscal year 2007, the Company anticipates that net sales will
grow to approximately $34 billion, an increase of 6% from prior
year net sales. The increase assumes a euro to U.S. dollar exchange
rate of $1.25, which is slightly higher than the average exchange
rate of $1.23 in fiscal year 2006.
-The Company expects building efficiency net sales to increase approximately
25% from the prior year, primarily due to the full year impact of
the York acquisition, service growth, enhanced global capabilities,
expansion into emerging markets and realization of acquisition synergies
from joint-selling and cross-selling a full range of product and
service offerings.
-The Company expects automotive experience net sales to decrease
approximately 3% to 5% from the prior year, primarily reflecting
lower revenue in North America. Lower industry production volume,
unfavorable vehicle mix between light trucks and passenger cars
and vehicle program rationalization are the key factors contributing
to the decrease.
-At September 30, 2006, automotive experience had an incremental
backlog of net new incremental business to be executed within the
next three fiscal years of $3.5 billion, $1.0 billion of which relates
to fiscal year 2007. The backlog is generally subject to a number
of risks and uncertainties, such as related vehicle production volumes
and the timing of
production launches.
-The Company expects power solutions net sales to increase approximately
5% from the prior year, primarily due to growth in the aftermarket
and the pass-through of higher lead prices.
Operating Margin
-The Company anticipates that the overall operating margin percentage
in fiscal year 2007 will increase from fiscal year 2006, excluding
restructuring costs. The margin improvement reflects the growth
and synergy realization in the building efficiency business.
-Except for volatility in lead prices, the Company expects other
key commodity costs, such as copper, steel, foam chemicals, resin
and fuel to be stable in fiscal year 2007, with the possibility
of some softening during the year.
-The Company expects building efficiency operating margin percentage
for fiscal year 2007 to improve as compared to the prior year, primarily
due to the realization of York integration cost synergies and restructuring
benefits, nonrecurring acquisition accounting expenses taken in
fiscal year 2006 and market growth initiatives in all operating
segments.
-The Company expects power solutions operating margin percentage
to be level with the prior year, primarily due to continued operational
efficiency improvements and benefits from the Delphi battery integration
offset by advanced technology spending and a favorable environmental
litigation settlement in the prior year.
-The Company expects automotive experience operating margin percentage
for fiscal year 2007 to decrease slightly compared to the prior
year, primarily due to lower production volumes, vehicle program
rationalization, unfavorable product mix in North America and higher
engineering and launch costs, partially offset by continued strong
performance in Europe. Automotive experience has supply agreements
with certain of its customers that provide for annual sales price
reductions and, in some instances, for the recovery of material
cost increases. The business expects to continue its historical
trend of being able to significantly offset any sales price changes
with cost reductions from design changes and productivity improvements
and through similar programs with its own suppliers.
R&D
(USD in million) | FY2006 | FY2005 | FY2004 |
Total | 743 | 817 | 844 |
Sponsored by customers | 323 | 402 | 352 |
Technology Centers (for Automotive Experience):
-Plymouth, Michigan USA
-Holland, Michigan USA
-Burscheid, Germany
-Pontoise, France
-Ayase, Japan
New Product Development
-In January 2006, the company announced that the Company's HomeLink
Wireless Control System with QuickTrain technology will be in production
on numerous 2007 model-year vehicles. The patented HomeLink system
is integrated into a vehicle's overhead console, sun visor or rear-view
mirror. With the addition of the QuickTrain feature, training the
HomeLink module is not only much easier, but it also takes less
time.
-In January 2005, the Company announced that it has developed a
new, highly durable type of foam pad for vehicle seating that improves
occupant comfort. The Company's VibraTech Foam product offers major
improvements in comfort, durability and craftsmanship. In addition,
thinner-profile seating can be created using VibraTech Foam, offering
the same or better comfort vs. current seats while freeing up valuable
space inside a vehicle's cabin. The VibraTech Foam product currently
is used in seats manufactured for Lexus RX330. Another automaker
will include VibraTech foam in a 2007 model-year vehicle.
- FastForward Seating System
FastForward Seating provides consumers with many options for modifying
their vehicle interiors. Second- and third-row seats can be used
in the upright position for transporting as many as six passengers.
In addition, these seats can be folded flat automatically in only
10 seconds, with the simple push of a button located either on a
key fob or in the rear area of the vehicle. FastForward Seating
provides high levels of occupant comfort in virtually every seat
location, thanks to its "Open Seating" technology. By
applying this technology, the Company can deliver the comfort and
styling reflected in industry-leading front seats to all seating
positions. The seats, which are thin and well-styled, offer enhanced
comfort via broad distribution of back pressure, as well as increased
lateral support that matches the support provided by front-row bucket
seats. The FastForward Seating System is available now for integration
into 2008 model-year vehicles.
- Hydride Battery
A 7.2-volt nickel-metal-hydride battery was developed using technologies
from the Company's Varta Battery Automotive Business in Europe,
where buses have run on the supplier's nickel-hydride batteries
for the past decade. Its new nickel-hydride battery incorporates
a more advanced design than the batteries used in busses and is
targeted to meet the power needs of sport utility vehicles and hybrid
models already on the market.
-Door Trim Module Concept
One of the benefits of this integrated approach is the lower weight
of the whole door system, since the door cassettes often used in
the past are no longer needed. The components can be integrated
directly into the ready-to-install door panel. In addition, the
number of assembly steps is reduced and a simplification of the
assembly process is achieved in the interface with the door.
-RIM alpha
In contrast to the conventional RIM (Reaction Injection Molding)
technique, which involves the use of two material components, RIM
alpha requires only one material, aliphatic polyurethane. This new
process enables production of a high-quality and cost-effective
molded skin that allows even very complex designs to be applied
over large surfaces.
-Tire Pressure Monitoring System
This system constantly monitors the air pressure of the tires, informing
the driver about the air pressure of all four tires via a convenient
display. The Company is supplying the new Renault Modus with this
system.
Investment Activities
Capital Expenditure (Year
ended September 30)
(USD in million) | FY2006 | FY2005 | FY2004 |
Overall | 711 | 664 | 817 |
Automotive experience - North America | 218 | 267 | 306 |
Automotive experience - Europe | 182 | 203 | 355 |
Automotive experience - Asia | 25 | 56 | 41 |
Power solution | 197 | 97 | 82 |