Certain statements under this caption of this Annual Report on Form 10-K constitute forward-looking statements within the meaning of the federal securities laws. As a general matter, forward-looking statements are those focused upon future plans, objectives or performance as opposed to historical items and include statements of anticipated events or trends and expectations and beliefs relating to matters not historical in nature. Such forward-looking statements involve known and unknown risks and are subject to uncertainties and factors relating toCore Molding Technologies' operations and business environment, all of which are difficult to predict and many of which are beyondCore Molding Technologies' control. Words such as "may," "will," "could," "would," "should," "anticipate," "predict," "potential," "continue," "expect," "intend," "plans," "projects," "believes," "estimates," "confident" and similar expressions are used to identify these forward-looking statements. These uncertainties and factors could causeCore Molding Technologies' actual results to differ materially from those matters expressed in or implied by such forward-looking statements.Core Molding Technologies believes that the following factors, among others, could affect its future performance and cause actual results to differ materially from those expressed or implied by forward-looking statements made in this Annual Report on Form 10-K: business conditions in the plastics, transportation, marine and commercial product industries (including slowdown in demand for truck production); federal and state regulations (including engine emission regulations); general economic, social, regulatory (including foreign trade policy) and political environments in the countries in whichCore Molding Technologies operates; safety and security conditions inMexico andCanada ; dependence upon certain major customers as the primary source ofCore Molding Technologies' sales revenues; efforts ofCore Molding Technologies to expand its customer base; the ability to develop new and innovative products and to diversify markets, materials and processes and increase operational enhancements; the actions of competitors, customers, and suppliers; failure ofCore Molding Technologies' suppliers to perform their obligations; the availability of raw materials; inflationary pressures; new technologies; regulatory matters; labor relations; the loss or inability ofCore Molding Technologies to attract and retain key personnel; the Company's ability to successfully identify, evaluate and manage potential acquisitions and to benefit from and properly integrate any completed acquisitions, including the recent acquisition of Horizon Plastics; the risk that the integration of Horizon Plastics may be more difficult, time-consuming or costly than expected; expected revenue synergies and cost savings from acquisition of Horizon Plastics may not be fully realized within the expected timeframe; revenues following the acquisition of Horizon Plastics may be lower than expected; customer and employee relationships and business operations may be disrupted by the acquisition of Horizon Plastics; federal, state and local environmental laws and regulations; the availability of capital; the ability ofCore Molding Technologies to provide on-time delivery to customers, which may require additional shipping expenses to ensure on-time delivery or otherwise result in late fees; risk of cancellation or rescheduling of orders; management's decision to pursue new products or businesses which involve additional costs, risks or capital expenditures; inadequate insurance coverage to protect against potential hazards; equipment and machinery failure; product liability and warranty claims; and other risks identified from time to time inCore Molding Technologies' other public documents on file with theSecurities and Exchange Commission , including those described in Item 1A of this Annual Report on Form 10-K.
DESCRIPTION OF THE COMPANY
Core Molding Technologies and its subsidiaries operate in the composites market as one operating segment as a molder of thermoplastic and thermoset structural products. The Company's operating segment consists of two component reporting units, Core Traditional and Horizon Plastics. The Company offers customers a wide range of manufacturing processes to fit various program volume and investment requirements. These processes include compression molding of sheet molding compound ("SMC"), bulk molding compounds ("BMC"), resin transfer molding ("RTM"), liquid molding of dicyclopentadiene ("DCPD"), spray-up and hand-lay-up, glass mat thermoplastics ("GMT"), direct long-fiber thermoplastics ("D-LFT") and structural foam and structural web injection molding ("SIM").Core Molding Technologies serves a wide variety of markets, including the medium and heavy-duty truck, marine, automotive, agriculture, construction, and other commercial products. Product sales to medium and heavy-duty truck markets accounted for 58% of the Company's sales for the year endedDecember 31, 2019 and 56% and 68% for the years endedDecember 31, 2018 and 2017, respectively. The demand forCore Molding Technologies' products is affected by economic conditions inthe United States ,Mexico , andCanada .Core Molding Technologies' manufacturing operations have a significant fixed cost component. Accordingly, during periods of changing demand, the profitability ofCore Molding Technologies' operations may change proportionately more than revenues from operations. In 1996,Core Molding Technologies acquired substantially all of the assets and assumed certain liabilities of Columbus Plastics, a wholly owned operating unit of Navistar's truck manufacturing division since its formation in late 1980. Columbus Plastics, located inColumbus, Ohio , was a compounder and compression molder of SMC. In 1998,Core Molding Technologies began operations at its second facility inGaffney, South Carolina , and in 2001,Core Molding Technologies added a production facility 24
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inMatamoros, Mexico by acquiring certain assets ofAirshield Corporation . As a result of this acquisition,Core Molding Technologies expanded its fiberglass molding capabilities to include the spray up, hand-lay-up open mold processes and RTM closed molding. In 2005,Core Molding Technologies acquired certain assets of theCincinnati Fiberglass Division of Diversified Glass , Inc., aBatavia, Ohio -based, privately held manufacturer and distributor of fiberglass reinforced plastic components supplied primarily to the heavy-duty truck market. In 2009, the Company completed construction of a new production facility inMatamoros, Mexico that replaced its leased facility. InMarch 2015 , the Company acquired substantially all of the assets ofCPI Binani, Inc. , a wholly owned subsidiary of Binani Industries Limited, located inWinona, Minnesota ("CPI"), which expanded the Company's process capabilities to include D-LFT and diversified the customer base. InJanuary 2018 , the Company acquired substantially all the assets of Horizon Plastics, which has manufacturing operations inCobourg, Ontario andEscobedo, Mexico . This acquisition expanded the Company's customer base, geographic footprint, and process capabilities to include structural foam and structural web molding.
BUSINESS OVERVIEW
General
The Company's business and operating results are directly affected by changes in overall customer demand, operational costs and performance and leverage of our fixed cost and selling, general and administrative ("SG&A") infrastructure. Product sales fluctuate in response to several factors including many that are beyond the Company's control, such as general economic conditions, interest rates, government regulations, consumer spending, labor availability, and our customers' production rates and inventory levels. Product sales consist of demand from customers in many different markets with different levels of cyclicality and seasonality. The North American truck market, which is highly cyclical, accounted for 58% and 56% of the Company's product revenue for the years endedDecember 31, 2019 and 2018, respectively. Operating performance is dependent on the Company's ability to manage changes in input costs for items such as raw materials, labor, and overhead operating costs. Performance is also affected by manufacturing efficiencies, including items such as on time delivery, quality, scrap, and productivity. Market factors of supply and demand can impact operating costs. In periods of rapid increases or decreases in customer demand, the Company is required to ramp operations activity up or down quickly which may impact manufacturing efficiencies more than in periods of steady demand. Operating performance is also dependent on the Company's ability to effectively launch new customer programs, which are typically extremely complex in nature. The start of production of a new program is the result of a process of developing new molds and assembly equipment, validation testing, manufacturing process design, development and testing, along with training and often hiring employees. Meeting the targeted levels of manufacturing efficiency for new programs usually occurs over time as the Company gains experience with new tools and processes. Therefore, during a new program launch period, start-up costs and inefficiencies can affect operating results. Results of 2019 OverviewCore Molding Technologies recorded a net loss in 2019 of$15,223,000 , or$(1.94) per basic and diluted share, compared with a net loss of$4,782,000 , or$(0.62) per basic and diluted share in 2018. Product sales in 2019 increased 5% from 2018, and operating income declined 272%. Higher demand from our truck and marine customers were the primary drivers of the sales increase, while the decrease in operating income was largely due to increased manufacturing inefficiencies at several of the Company's facilities, a higher goodwill impairment charge, and higher operating and SG&A costs. In the second half of 2018, the Company started experiencing manufacturing inefficiencies as a result of the significant production demand in the heavy-duty truck market. Given the high demand levels, the Company experienced difficulty hiring, training and retaining labor in a tightening labor market at several manufacturing facilities. This, coupled with asset capacity and reliability constraints, resulted in increased manufacturing inefficiencies and the inability to consistently meet customers' delivery and quality requirements, including for several of the Company's major customers. During the fourth quarter of 2018, the Company hired a new CEO who began to implement a turnaround plan to improve customer delivery and quality performance and reduce manufacturing inefficiencies. The turnaround plan included additional spending to improve equipment and labor stability. Management believes that during 2019 the operational benefits of the turnaround plan are being realized as customer delivery and quality levels have begun to improve. While management believes these improvements have been successful as an operational matter and were the primary focus of the turnaround plan, operational efficiency improvements at the plants have not yet resulted in anticipated levels of financial improvements. The Company's financial performance had started to reflect the benefits of the turnaround improvements during the third quarter of 2019, however sales volumes from products were 19% lower in the fourth quarter, as compared to the third quarter, which had an adverse effect on operating income in the fourth quarter. 25
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As part of the turnaround plan, management has implemented customer price increases where margin on product is not meeting the Company's profitability model, and are evaluating relationships with major customers to assess ongoing profitability of those relationships. The Company previously announced that onNovember 15, 2019 it had provided notice to theVolvo Group ("Volvo") of the Company's intention to terminate its agreement with Volvo, with such termination to become effective twelve months from the date of notice, absent the parties reaching mutually agreeable terms upon which to continue their relationship. InMarch 2020 , the Company and Volvo mutually agreed to new terms to continue to supply Volvo and the Company revoked its termination notice. Sales to Volvo amounted to approximately 17%, 17%, and 22% of total sales for 2019, 2018, and 2017, respectively. Looking forward, the Company anticipates that 2020 product sales levels will decrease as compared to 2019, due to lower demand from heavy duty truck customers. Heavy duty truck customers as well as industry analysts are forecasting a decrease in Class 8 truck sales of approximately 34% in 2020 compared to 2019. Management continues to aggressively implement the Company's turnaround plan to improve operational inefficiencies and financial performance while still managing and reacting to the softening truck production forecasts. 2019 Compared to 2018 Net sales for 2019 totaled$284,290,000 , which was an increase from the$269,485,000 reported for 2018. Included in total sales were tooling project sales of$15,303,000 for 2019 and$13,268,000 for 2018. Tooling project sales result primarily from customer approval and acceptance of molds and assembly equipment specific to their products as well as other non-production services. These sales are sporadic in nature and fluctuate in regard to scope and related revenue on a period-to-period basis. Total product sales for 2019, excluding tooling project sales, totaled$268,987,000 , representing a 5% increase from the$256,217,000 reported for 2018. The increase in product sales is primarily the result of increased sales to our truck and marine customers of$11,707,000 and$3,144,000 , respectively. Gross margin was approximately 7.6% of sales in 2019 and 10.1% in 2018. The gross margin decrease, as a percent of sales, was due to unfavorable product mix and production inefficiencies of 4.2%. These reductions were offset by net changes in selling price and material costs of 1.3% and favorable changes in customer chargebacks of 0.4%. Selling, general and administrative expense ("SG&A") totaled$28,934,000 in 2019, compared to$27,838,000 in 2018. The increase in SG&A expense primarily resulted from higher labor and benefit costs of$1,144,000 and higher insurance costs of$327,000 offset by lower professional and outside services of$1,017,000 . For the year endedDecember 31, 2018 , the Company incurred one-time acquisition fees of$1,289,000 .
Net interest expense totaled$4,144,000 for the year endedDecember 31, 2019 , compared to net interest expense of$2,394,000 for the year endedDecember 31, 2018 . The increase in interest expense was primarily due to a higher average outstanding debt balance as well has higher interest rates in 2019. Income tax benefit was approximately 2% of total loss before income taxes in 2019 and 12% in 2018. The effective income tax rate in both years is a result of the net effect of taxable losses in a lower statutory rate tax jurisdictions being offset by taxable income in higher statutory rate tax jurisdictions. Additionally, the effective rate in 2019 includes the impact of recording a full valuation allowance against net deferred tax assets inthe United States of approximately$3,267,000 .
Net loss for 2019 was
Comprehensive loss totaled$15,970,000 in 2019, compared to a comprehensive loss of$4,735,000 in 2018. The decrease was primarily related to higher net loss of$10,441,000 and a change in net actuarial adjustments of$1,630,000 for other post-retirement benefit obligations offset by a change in hedging derivatives of$836,000 . The net actuarial changes in 2018 and 2019 were primarily due to changes in discount rate. 2018 Compared to 2017 Net sales for 2018 totaled$269,485,000 , which was an increase from the$161,673,000 reported for 2017. Included in total sales were tooling project sales of$13,268,000 for 2018 and$13,050,000 for 2017. Tooling project sales result primarily from customer approval and acceptance of molds and assembly equipment specific to their products as well as other non-production services. These sales are sporadic in nature and fluctuate in regard to scope and related revenue on a period-to-period basis. Total product sales for 2018, excluding tooling project sales, totaled$256,217,000 , representing a 72% increase from the$148,623,000 reported 26
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for 2017. The increase in product sales is primarily the result of new sales from the acquisition of Horizon Plastics totaling$62,603,000 and higher demand from truck customers of$44,991,000 . Gross margin was approximately 10.1% of sales in 2018 and 15.2% in 2017. The gross margin decrease, as a percent of sales, was due to unfavorable product mix and production inefficiencies of 8.1%, net changes in selling price and material costs of 1.1% and unfavorable sales returns of 0.6%, offset by higher leverage of fixed costs of 2.5% and favorable impact of 2.0% from the Horizon Plastic acquisition.
Selling, general and administrative expense ("SG&A") totaled
Goodwill impairment totaled$2,403,000 in 2018, based on the Company's annual goodwill impairment assessment for the Core Traditional reporting unit. See Note 2 - Summary of Significant Accounting Policies, for further details. Net interest expense totaled$2,394,000 for the year endedDecember 31, 2018 , compared to net interest expense of$245,000 for the year endedDecember 31, 2017 . The increase in interest expense was primarily due to a higher average outstanding debt balance in 2018. Income tax expense was approximately 12% of total income before income taxes in 2018 and 30% in 2017. The change in effective income tax rate primary relates to the net effect of taxable losses in a lower statutory rate tax jurisdictions being offset by taxable income in higher statutory rate tax jurisdictions.
Net loss for 2018 was
Comprehensive loss totaled$4,735,000 in 2018, compared to comprehensive income of$4,953,000 in 2017. The decrease was primarily related to lower net income of$10,241,000 and a change in hedging derivatives of$418,000 offset by a change in net actuarial adjustments of$971,000 for other post-retirement benefit obligations. In 2018, the Company recorded a net actuarial gain of$910,000 compared to an actuarial loss of$417,000 in 2017. The 2018 gain and the 2017 loss were primarily due to a change in discount rate.
LIQUIDITY AND CAPITAL RESOURCES
Cash Flow The Company's primary sources of funds have been cash generated from operating activities and borrowings from third parties. Primary cash requirements are for operating expenses, capital expenditures, repayments of debt, and acquisitions. The Company from time to time will enter into foreign exchange contracts and interest rate swaps to mitigate risk of foreign exchange and interest rate volatility. As ofDecember 31, 2019 , the Company had outstanding foreign exchange contracts with notional amounts totaling$15,358,000 , compared to$27,588,000 outstanding as ofDecember 31, 2018 . As ofDecember 31, 2019 , the Company also had outstanding interest rate swaps with notional amounts totaling$29,750,000 , compared to$32,375,000 outstanding as ofDecember 31, 2018 . Cash provided by operating activities totaled$16,701,000 for the year endedDecember 31, 2019 . Net loss of$15,223,000 negatively impacted operating cash flows. Non-cash deductions of depreciation and amortization, and goodwill impairment charge included in net loss amounted to$10,376,000 and$4,100,000 , respectively. Decreases in working capital resulted in cash provided by operating activities of$18,285,000 . Changes in working capital primarily related to decreases in accounts receivable and inventory, due to a decreases in sales volume and reduction in certain customer payment terms. Cash used in investing activities totaled$7,460,000 for the year endedDecember 31, 2019 , primarily related to purchases of property, plant and equipment for new programs and equipment improvements at the Company's production facilities. The Company anticipates spending approximately$9,000,000 during 2020 on property, plant and equipment purchases for all of the Company's operations. The Company anticipates using cash from operations and its revolving line of credit to finance this capital investment. AtDecember 31, 2019 , purchase commitments for capital expenditures in progress were approximately$336,000 .
Cash used in financing activities totaled
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AtDecember 31, 2019 , the Company had$1,856,000 of cash on hand and an available revolving line of credit of$15,992,000 . If a material adverse change in the financial position of the Company should occur, or if actual sales or expenses are substantially different than what has been forecasted, the Company's liquidity and ability to obtain further financing to fund future operating and capital requirements could be negatively impacted. Debt and Credit Facilities OnJanuary 16, 2018 , the Company entered into an Amended and Restated Credit Agreement (the "A/R Credit Agreement") withKeyBank National Association as administrative agent (the "Administrative Agent") and various financial institutions party thereto as lenders (the "Lenders"). Pursuant to the terms of the A/R Credit Agreement (i) the Company may borrow revolving loans in the aggregate principal amount of up to$40,000,000 (the "U.S. Revolving Loans") from the Lenders and term loans in the aggregate principal amount of up to$32,000,000 from the Lenders, (ii) the Company's wholly-owned subsidiary,Horizon Plastics International, Inc. , (the "Subsidiary") may borrow revolving loans in an aggregate principal amount of up to$10,000,000 from the Lenders (which revolving loans shall reduce the availability of theU.S. Revolving Loans to the Company on a dollar-for-dollar basis) and term loans in an aggregate principal amount of up to$13,000,000 from the Lenders, (iii) the Company obtained a Letter of Credit Commitment of$250,000 , of which$160,000 has been issued and (iv) the Company repaid the outstanding term loan balance of$6,750,000 . The A/R Credit Agreement is secured by a guarantee of eachU.S. and Canadian subsidiary of the Company, and by a lien on substantially all of the present and future assets of the Company and itsU.S. and Canadian subsidiaries, except that only 65% of the stock issued by Corecomposites deMexico ,S. de R.L. de C.V. has been pledged. Concurrent with the closing of the A/R Credit Agreement the Company borrowed the$32,000,000 term loan and$2,000,000 from theU.S. Revolving loan and the Subsidiary borrowed the$13,000,000 term loan and$2,500,000 from revolving loans to provide$49,500,000 of funding for the acquisition of Horizon Plastics. OnMarch 14, 2019 , the Company entered into the first amendment ("First Amendment") to the A/R Credit Agreement with the Lenders. Pursuant to the terms of the First Amendment, the Company and Lenders agreed to modify certain terms of the A/R Credit Agreement. These modifications included (1) implementation of an availability block on theU.S. Revolving Loans reducing availability from$40,000,000 to$32,500,000 , (2) modification to the definition of EBITDA to add back certain one-time expenses, (3) waiver of non-compliance with the leverage covenant as ofDecember 31, 2018 and modification of the leverage ratio definition and covenant to eliminate testing of the leverage ratio untilDecember 31, 2019 , (4) waiver of non-compliance with the fixed charge covenant as ofDecember 31, 2018 and modification of the fixed charge coverage ratio definition and covenant requirement, (5) implementation of a capital expenditure spend limit of$7,500,000 during the first six months of 2019 and$12,500,000 for the full year 2019, (6) an increase of the applicable interest margin spread for existing term and revolving loans, and (7) an increase in the commitment fees on any unusedU.S. Revolving Loans. OnNovember 22, 2019 , the Company entered into a forbearance agreement (the "Forbearance Agreement") with the Lenders. Pursuant to the Forbearance Agreement, the Borrowers and the Lenders acknowledged and confirmed that an event of default occurred under the A/R Credit Agreement resulting from the Borrowers failure to maintain the required Fixed Charge Coverage Ratio (as defined in the A/R Credit Agreement") for the fiscal quarter endedSeptember 30, 2019 . The Forbearance Agreement provides that the Administrative Agent and Lenders shall forbear from the exercise of rights and remedies pursuant to the Loan Documents described in the A/R Credit Agreement throughMarch 13, 2020 , as long as the Company satisfies the conditions set forth in the Forbearance Agreement, including, (i) the Borrowers shall remain current on all loan payments during the forbearance period, (ii) on or beforeDecember 6, 2019 , the Administrative Agent and Lenders shall each receive a copy of a report of Huron Consulting Group containing findings and observations in respect of the businesses and operations of the Company and the Borrowers shall deliver a strategic alternative assessment in respect of the Borrowers' operations and financing, (iii) on or beforeDecember 15, 2019 , the Administrative Agent and Lenders shall each receive a copy of appraisals of machinery and equipment and inventory appraisals, and the Borrowers shall have determined and proposed a new capital structure to the Administrative Agent and Lenders, (iv) on or beforeFebruary 14, 2020 , the Borrowers shall have obtained a definitive, written commitment from involved parties and/or lenders providing the basis for implementation of a new capital structure, and (v) on or beforeMarch 13, 2020 , the Borrowers shall have closed on a new capital structure, acceptable to the Administrative Agents and Lenders. The Forbearance Agreement also implemented a new availability block with respect to theU.S. Revolving Loans portion of the A/R Credit Agreement, reducing availability from$32,500,000 to$28,000,000 and increasing the applicable margin for existing term and revolving loans, as well as increasing the commitment fees on any unusedU.S. Revolving Loans. OnMarch 13, 2020 , the Company entered into an Amendment to the Forbearance Agreement (the "Amended Forbearance Agreement") with the Lenders. Pursuant to the terms of the Amended Forbearance Agreement, the Company and Lenders agreed to modify certain terms of the A/R Credit Agreement and Forbearance Agreement and extend the Forbearance Agreement throughMay 29, 2020 . The modifications include (1) a reduction in theU.S. Revolving Loan to$25,000,000 with an availability block of$5,000,000 which can be borrowed with the unanimous approval of the lenders, (2) a change of interest rate to LIBOR plus 650 basis points for all outstanding loans, (3) forbear compliance with the leverage covenant and fixed charge covenant throughMay 28
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29, 2020, and (4) implementation of a capital expenditure spend limit of
The Amended Forbearance Agreement provides that the Administrative Agent and Lenders shall forbear from the exercise of rights and remedies pursuant to the Loan Documents described in the Credit Agreement throughMay 29, 2020 , as long as the Company satisfies the conditions set forth in the Amended Forbearance Agreement, including, (i) on or beforeMarch 31, 2020 , the borrowers shall have obtained an executed term sheet from involved parties and/or lenders providing the basis for implementation of a new capital structure and defined due diligence parameters, (ii) on or beforeMay 15, 2020 the Borrowers shall have obtained an executed definitive, written commitment from the New Lenders to enter into a definitive agreement to effect the refinancing, and (iii) on or beforeMay 29, 2020 , the borrowers shall have closed on a new capital structure. As a result of the Amended Forbearance Agreement not extending beyond a year, the Company's remaining long-term debt under the A/R Credit Agreement, consisting of$49,451,000 in borrowings under the revolving credit commitment and the loan commitments, was classified as a current liability in the Company's consolidated balance sheet as ofDecember 31, 2019 . As a result, the Company's current liabilities exceeded its current assets by$22,609,000 as ofDecember 31, 2019 . If the Lenders were to call the loans or demand repayment of all existing borrowings, this could result in the Company being unable to meet its working capital obligations. Bank Covenants The Company is required to meet certain financial covenants included in the A/R Credit Agreement with respect to leverage ratios, fixed charge ratios and capital expenditures. As ofSeptember 30, 2019 , the Company was in default with its fixed charge coverage ratios associated with the loans made under the A/R Credit Agreement as described above. As a result of this default the Company and the Administrative Agent on behalf of the Lenders entered into a Forbearance Agreement to address the non-compliance and establish milestones for the Company related to restructuring of its existing debt. EffectiveMarch 13, 2020 , the Company entered into an Amended Forbearance Agreement to modify existing and establish new milestones. The Company is required to meet certain financial covenants included in the A/R Credit Agreement with respect to leverage ratios and fixed charge ratios and capital expenditures, as well as other customary affirmative and negative covenants. As ofSeptember 30, 2019 , the Company was not in compliance with its financial covenants. The following table presents the financial covenants specified in our A/R Credit Agreement, as modified by the First Amendment, and the actual covenant calculations as ofDecember 31, 2019 : Actual
Covenants as
Financial Covenants of December 31, 2019 Fixed Charge Coverage Ratio (A) Minimum 1.00 0.59 Leverage Ratio 3.25 or Lower 9.18 (A) The terms of the A/R Credit Agreement that the fixed charge coverage ratio will be maintained at a minimum of 1.00 and 1.10 on each ofDecember 31, 2019 andMarch 31, 2020 , and fromJune 30, 2020 and thereafter set at a minimum of 1.15. The Amended A/R Credit Agreement also provides a capital expenditure limit covenant, whereby capital expenditures as defined in the Amended A/R Credit Agreement are limited to an aggregate of$12,500,000 for the twelve months endedDecember 31, 2019 . As ofDecember 31, 2019 capital expenditures for 2019 have amounted to$7,460,000 . Based on current financial projections, the Company does not believe that it will be compliant with the financial covenants beyond the negotiated forbearance period and therefore is pursuing the restructuring or refinancing of its existing obligations under the A/R Credit Agreement. The Company has engaged Huron Transactional Advisor's to facilitate a full marketing process for refinancing the A/R Credit Agreement. Management and Huron are evaluating term sheets submitted by potential lending sources. The Company is considering financing options including an asset backed lending facility using the Company's accounts receivable and inventories as security, term loans secured with the Company's real estate and machinery and equipment, sale and leaseback of Company owned real estate and potential equity financing. Any new financing remains subject to asset appraisals, field exams, financial projection due diligence, real estate environmental reviews, and other customary legal documentation. 29
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Shelf Registration OnNovember 14, 2017 the Company filed a universal shelf Registration Statement on Form S-3 (the "Registration Statement") with theSEC in accordance with the Securities Act of 1933, as amended, which became effective onNovember 20, 2017 . The Registration Statement registered common stock, preferred stock, debt securities, warrants, depositary shares, rights, units, and any combination of the foregoing, for a maximum aggregate offering price of up to$50 million , which may be sold from time to time. The terms of any securities offered under the Registration Statement and intended use of proceeds will be established at the times of the offerings and will be described in prospectus supplements filed with theSEC at the times of the offerings. The Registration Statement has a three year term.
CONTRACTUAL OBLIGATIONS AND OFF-BALANCE SHEET TRANSACTIONS
The Company has the following minimum commitments under contractual obligations, including purchase obligations, as defined by theSEC . A "purchase obligation" is defined as an agreement to purchase goods or services that is enforceable and legally binding on the Company and that specifies all significant terms, including: fixed or minimum quantities to be purchased; fixed, minimum, or variable price provisions; and the approximate timing of the transaction. Other long-term liabilities are defined as long-term liabilities that are reflected on the Company's balance sheet under accounting principles generally accepted inthe United States . Based on this definition, the table below includes only those contracts which include fixed or minimum obligations. It does not include normal purchases, which are made in the ordinary course of business.
The following table provides aggregated information about the maturities of
contractual obligations and other long-term liabilities as of
2020 2021 2022 2023 2024 and after Total Long-term debt(C)$ 49,451,000 $ - $ - $ - $ -$ 49,451,000 Interest(A)(C) 2,740,000 - - - - 2,740,000 Operating lease 1,433,000 1,174,000 1,102,000 1,000,000 530,000 5,239,000 obligations Contractual commitments for 336,000 - - - - 336,000 capital expenditures(B) Post retirement 1,233,000 470,000 497,000 519,000 6,441,000 9,160,000 benefits Total$ 55,193,000 $ 1,644,000 $ 1,599,000 $ 1,519,000 $ 6,971,000 $ 66,926,000
(A) Variable interest rates were as of
As of
CRITICAL ACCOUNTING POLICIES AND ESTIMATES
Management's Discussion and Analysis of Financial Condition and Results of Operations discuss the Company's consolidated financial statements, which have been prepared in accordance with accounting principles generally accepted inthe United States . The preparation of these consolidated financial statements requires management to make estimates and assumptions that affect the reported amounts of assets and liabilities and the disclosure of contingent assets and liabilities at the date of the consolidated financial statements and the reported amounts of revenues and expenses during the reporting period. On an on-going basis, management evaluates its estimates and judgments, including those related to accounts receivable, inventories, goodwill and other long-lived assets, self-insurance, post retirement benefits, and income taxes. Management bases its estimates and judgments on historical experience and on various other factors that are believed to be reasonable under the circumstances, the results of which form the basis for making judgments about the carrying value of assets and liabilities that are not readily apparent from other sources. Actual results may differ from these estimates under different assumptions or conditions. Management believes the following critical accounting policies, among others, affect its more significant judgments and estimates used in the preparation of its consolidated financial statements. 30
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Accounts Receivable Allowances Management maintains allowances for doubtful accounts for estimated losses resulting from the inability of its customers to make required payments. If the financial condition of the Company's customers were to deteriorate, resulting in an impairment of their ability to make payments, additional allowances may be required. The Company has determined that a$50,000 allowance for doubtful accounts is needed atDecember 31, 2019 and$25,000 allowance was needed atDecember 31, 2018 . Management also records estimates for customer returns and deductions, discounts offered to customers, and for price adjustments. Should customer returns and deductions, discounts, and price adjustments fluctuate from the estimated amounts, additional allowances may be required. The Company had an allowance for estimated chargebacks of $$476,000 atDecember 31, 2019 and $$2,344,000 atDecember 31, 2018 . There have been no material changes in the methodology of these calculations.
Inventories
Inventories, which include material, labor and manufacturing overhead, are valued at the lower of cost or net realizable value. The inventories are accounted for using the first-in, first-out (FIFO) method of determining inventory costs. Inventory quantities on-hand are regularly reviewed, and where necessary, provisions for excess and obsolete inventory are recorded based on historical and anticipated usage. The Company has recorded an allowance for slow moving and obsolete inventory of$898,000 atDecember 31, 2019 and$957,000 atDecember 31, 2018 . Long-Lived Assets Long-lived assets consist primarily of property, plant and equipment and finite-lived intangibles. The Company acquired substantially all of the assets of Horizon Plastics onJanuary 16, 2018 , which resulted in approximately$16,770,000 of finite-lived intangibles and$12,994,000 of property, plant and equipment, all of which were recorded at fair value. The recoverability of long-lived assets is evaluated by an analysis of operating results and consideration of other significant events or changes in the business environment. The Company evaluates, whether impairment exists for long-lived assets on the basis of undiscounted expected future cash flows from operations before interest. There was no impairment of the Company's long-lived assets for the years endedDecember 31, 2019 , 2018 and 2017.
The purchase consideration of acquired businesses have been allocated to the assets and liabilities acquired based on the estimated fair values on the respective acquisition dates. Based on these values, the excess purchase consideration over the fair value of the net assets acquired was allocated to goodwill. The Company accounts for goodwill in accordance with FASB ASC Topic 350, Intangibles -Goodwill and Other. FASB ASC Topic 350 prohibits the amortization of goodwill and requires these assets be reviewed for impairment at each reporting unit. As a result of the Horizon Plastics acquisition onJanuary 16, 2018 and the status of its integration, the Company established two reporting units, Core Traditional and Horizon Plastics. The annual impairment tests of goodwill may be completed through qualitative assessments, however the Company may elect to bypass the qualitative assessment and proceed directly to a quantitative impairment test for any reporting unit in any period. The Company may resume the qualitative assessment for any reporting unit in any subsequent period. Under a qualitative and quantitative approach, the impairment test for goodwill consists of an assessment of whether it is more-likely-than-not that a reporting unit's fair value is less than its carrying amount. As part of the qualitative assessment, the Company considers relevant events and circumstances that affect the fair value or carrying amount of the Company. Such events and circumstances could include macroeconomic conditions, industry and market conditions, cost factors, overall financial performance, reporting unit specific events and capital markets pricing. The Company places more weight on the events and circumstances that most affect the Company's fair value or carrying amount. These factors are all considered by management in reaching its conclusion about whether to perform step one of the impairment test. If the Company elects to bypass the qualitative assessment for any reporting unit, or if a qualitative assessment indicates it is more-likely-than-not that the estimated carrying value of a reporting unit exceeds its fair value, the Company proceeds to a quantitative approach. Due to the Company's financial performance and continued depressed stock price, the Company performed a quantitative analysis for both of its reporting units atSeptember 30, 2019 . During 2019, the Company incurred a loss of margin in its Horizon Plastics reporting unit caused by selling price decreases that the Company has not been able to fully offset with material cost reductions. As a result of the quantitative analysis, the Company concluded that the carrying value of Horizon Plastics was greater than the fair value, which resulted in a goodwill impairment charge of$4,100,000 atSeptember 30, 2019 representing 19% of the goodwill related to the Horizon Plastics reporting unit. The company performed a qualitative assessment atDecember 31, 2019 , indicating no additional goodwill impairment related to the Horizon Plastics reporting unit. The Company's annual impairment assessment atDecember 31, 2018 consisted of a quantitative analysis for both reporting units. It concluded that the carrying value of Core Traditional was greater than the fair value, which resulted in a goodwill impairment charge of$2,403,000 , representing all the goodwill related to the Core Traditional reporting unit. The analysis of the Company's other reporting unit, Horizon Plastics, indicated no goodwill impairment charge, based on historical performance and financial 31
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projections at that time, as the excess of the estimated fair value over the carrying value of its invested capital was approximately 23% of the book value of its net assets. There was impairment of the Company's goodwill in 2019 and 2018 of$4,100,000 and$2,403,000 , respectively. There was no impairment of the Company's goodwill for the year endedDecember 2017 .
The Company is self-insured with respect toColumbus andBatavia, Ohio ,Gaffney, South Carolina ,Winona, Minnesota andBrownsville, Texas for medical, dental and vision claims andColumbus andBatavia, Ohio for workers' compensation claims, all of which are subject to stop-loss insurance thresholds. The Company is also self-insured for dental and vision with respect to itsCobourg, Canada location. The Company has recorded an estimated liability for self-insured medical, dental and vision claims incurred but not reported and worker's compensation claims incurred but not reported atDecember 31, 2019 andDecember 31, 2018 of$1,203,000 and$960,000 , respectively. Post Retirement Benefits Management records an accrual for post retirement costs associated with the health care plan sponsored by the Company for certain employees. Should actual results differ from the assumptions used to determine the reserves, additional provisions may be required. In particular, increases in future healthcare costs above the assumptions could have an adverse effect on the Company's operations. The effect of a change in healthcare costs is described in Note 13 - Post Retirement Benefits,Core Molding Technologies had a liability for post retirement healthcare benefits based on actuarially computed estimates of$9,160,000 atDecember 31, 2019 and$8,076,000 atDecember 31, 2018 . Revenue Recognition The Company historically has recognized revenue from two streams, product revenue and tooling revenue. Product revenue is earned from the manufacture and sale of sheet molding compound and thermoset and thermoplastic products. Revenue from product sales is generally recognized as products are shipped, as the Company transfers control to the customer and is entitled to payment upon shipment. In certain circumstances, the Company recognizes revenue from product sales when products are produced and the customer takes control at our production facility. Tooling revenue is earned from manufacturing multiple tools, molds and assembly equipment as part of a tooling program for a customer. Given that the Company is providing a significant service of producing highly interdependent component parts of the tooling program, each tooling program consists of a single performance obligation to provide the customer the capability to produce a single product. Based on the arrangement with the customer, the Company recognizes revenue either at a point in time or over time. When the Company does not have an enforceable right to payment, the Company recognizes tooling revenue at a point in time. In such cases, the Company recognizes revenue upon customer acceptance, which is when the customer has legal title to the tools. The Company historically recognized all tooling revenue at a point in time, upon customer acceptance, before the adoption of ASU 2014-09. Certain tooling programs include an enforceable right to payment. In those cases, the Company recognizes revenue over time based on the extent of progress towards completion of its performance obligation. The Company uses a cost-to-cost measure of progress for such contracts because it best depicts the transfer of value to the customer and also correlates with the amount of consideration to which the entity expects to be entitled in exchange for transferring the promised goods or services to the customer. Under the cost-to-cost measure of progress, progress towards completion is measured based on the ratio of costs incurred to date to the total estimated costs at completion of the performance obligation. Revenues are recorded proportionally as costs are incurred. Income Taxes The Company evaluates the balance of deferred tax assets that will be realized based on the premise that the Company is more likely than not to realize deferred tax benefits through the generation of future taxable income. Management reviews all available evidence, both positive and negative, to assess the long-term earnings potential of the Company using a number of alternatives to evaluate financial results in economic cycles at various industry volume conditions. Other factors considered are the Company's relationships with its major customers, and any recent customer diversification efforts. The projected availability of taxable income to realize the tax benefits from the reversal of temporary differences before expiration of these benefits are also considered. The Company evaluates provisions and deferred tax assets quarterly to determine if adjustments to our valuation allowance are required based on the consideration of all available evidence. As ofDecember 31, 2019 the Company had a deferred tax asset of$5,293,000 of which$3,267,000 is related to tax positions inthe United States ,$1,555,000 related to tax positions inCanada and$471,000 related to tax positions inMexico . During 2019, the Company recorded a valuation allowance against all deferred tax assets inthe United States , due to cumulative losses over the last three years and uncertainty related to the Company's ability to realize net loss carryforwards and other net deferred tax 32
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assets in the future. The Company believes that the deferred tax assets associated with the Canadian and Mexican tax jurisdictions are more-likely-than-not to be realizable based on estimates of future taxable income and the Company's ability to carryback losses.
Management recognizes the financial statement effects of a tax position when it is more likely than not the position will be sustained upon examination.
Recent Accounting Pronouncements Leases InFebruary 2016 , theFinancial Accounting Standards Board issued Accounting Standards Update ("ASU") No. 2016-02, Leases (Topic 842). This update requires organizations to recognize lease assets and lease liabilities on the balance sheet and also disclose key information about leasing arrangements. This ASU is effective for annual reporting periods beginning on or afterDecember 15, 2018 , and interim periods within those annual periods. Earlier application is permitted for all entities as of the beginning of an interim or annual period. In accordance with ASU 2016-02, the Company elected not to recognize lease assets and lease liabilities for leases with a term of twelve months or less. The ASU requires a modified retrospective transition method, or a transition method option further described within ASU 2018-11, with the option to elect a package of practical expedients that permits the Company to: (1) not reassess whether expired or existing contracts contain leases, (2) not reassess lease classification for existing or expired leases and (3) not consider whether previously capitalized initial direct costs would be appropriate under the new standard. The Company elected to apply the package of practical expedients. The Company adopted ASU No. 2016-02 as ofJanuary 1, 2019 , using the modified retrospective approach. The modified retrospective approach provides a method for recording existing leases at adoption without restating previously reported periods. In addition, the Company elected the practical expedients permitted under the transition guidance within the new standard, which among other things, allowed the Company to carry forward the historical lease classification. In addition, the Company elected the practical expedient to determine the lease term for existing leases. In the application of practical expedient, the Company evaluated the buildings leased and the current financial performance of the plant associated, which resulted in the determination that most renewal options would be reasonably certain in determining the expected lease term. Adoption of the new standard resulted in the recording of additional net right of use assets and lease liabilities of$4,490,000 and$4,428,000 , respectively, as ofJanuary 1, 2019 . The present value of lease liabilities has been measured using the Company's revolving loan borrowing rates as ofDecember 31, 2018 (one day prior to initial application). Additionally, ROU assets for these operating leases have been measured as the initial measurement of applicable lease liabilities adjusted for any unamortized initial prepaid/accrued rent and any ASC Topic 420 liabilities. The standard did not materially impact the Company's consolidated statement of income (loss) or statement of cash flows. Current expected credit loss (CECL) InJune 2016 , the FASB issued ASU 2016-13, "Financial Instruments-Credit Losses," which changes the impairment model for most financial assets and certain other instruments. For trade and other receivables, held-to-maturity debt securities, loans and other instruments, entities will be required to use a new forward-looking "expected loss" model that will replace today's "incurred loss" model and generally will result in the earlier recognition of allowances for losses. For available-for-sale debt securities with unrealized losses, entities will measure credit losses in a manner similar to current practice, except that the losses will be recognized as an allowance. Subsequent to issuing ASU 2016-13, the FASB issued ASU 2018-19, "Codification Improvements to Topic 326, Financial Instruments - Credit Losses," for the purpose of clarifying certain aspects of ASU 2016-13. ASU 2018-19 has the same effective date and transition requirements as ASU 2016-13. InApril 2019 , the FASB issued ASU 2019-04, "Codification Improvements to Topic 326, Financial Instruments - Credit Losses, Topic 815, Derivatives and Hedging, and Topic 825, Financial Instruments," which is effective with the adoption of ASU 2016-13. InMay 2019 , the FASB issued ASU 2019-05, "Financial Instruments - Credit Losses (Topic 326)," which is also effective with the adoption of ASU 2016-13. InOctober 2019 , the FASB voted to delay the implementation date for certain companies, including those that qualify as a smaller reporting company underSEC rules, untilJanuary 1, 2023 , with revised ASU's expected to be issued inNovember 2019 . We will adopt this ASU on its effective date ofJanuary 1, 2023 . We do not expect the adoption of this ASU to have a material impact on our consolidated financial position, results of operations, cash flows, or presentation thereof. 33
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