AXL 2011 10K w/ NR&S
UNITED STATES
SECURITIES AND EXCHANGE COMMISSION
WASHINGTON, D.C. 20549

FORM 10-K

/X/ ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934
For the fiscal year ended December 31, 2011

or

/ / TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934
For the transition period from _______ to _______

Commission file number 1-14303

AMERICAN AXLE & MANUFACTURING HOLDINGS, INC.
(Exact name of registrant as specified in its charter)
DELAWARE
 
38-3161171
(State or other jurisdiction of
 
(I.R.S. Employer
incorporation or organization)
 
Identification No.)
 
 
 
ONE DAUCH DRIVE, DETROIT, MICHIGAN
 
48211-1198
(Address of principal executive offices)
 
(Zip Code)
313-758-2000
(Registrant's telephone number, including area code)
Securities registered pursuant to Section 12(b) of the Act:
Title of Each Class
 
Name of Each Exchange on Which Registered
COMMON STOCK, PAR VALUE $0.01 PER SHARE
 
NEW YORK STOCK EXCHANGE
PREFERRED SHARE PURCHASE RIGHTS, PAR VALUE $0.01 PER SHARE
 
NEW YORK STOCK EXCHANGE
Securities registered pursuant to Section 12(g) of the Act: None

Indicate by check mark if the registrant is a well-known seasoned issuer, as defined in Rule 405 of the Securities Act. Yes x No o

Indicate by check mark if the registrant is not required to file reports pursuant to Section 13 or Section 15(d) of the Exchange Act. Yes o No x

Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for such shorter period that the registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days. Yes x No o

Indicate by check mark whether the registrant has submitted electronically and posted on its corporate Web site, if any, every Interactive Data File required to be submitted and posted pursuant to Rule 405 of Regulation S-T (§ 232.405 of this chapter) during the preceding 12 months (or for such shorter period that the registrant was required to submit and post such files). Yes x No o

Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of registrant's knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K. x

Indicate by check mark whether the registrant is a large accelerated filer, an accelerated filer, a non-accelerated filer or a smaller reporting company. See definition of “accelerated filer”, “large accelerated filer” and “smaller reporting company” in Rule 12b-2 of the Exchange Act).    
Large accelerated filer x Accelerated filer o Non-accelerated filer o Smaller reporting company o
(Do not check if small reporting company)

Indicate by check mark whether the registrant is a shell company (as defined in Rule 12b-2 of the Exchange Act). Yes o No x

The closing price of the Common Stock on June 30, 2011 as reported on the New York Stock Exchange was $11.38 per share and the aggregate market value of the registrant's Common Stock held by non-affiliates was approximately $785.5 million.

As of February 6, 2012, the number of shares of the registrant's Common Stock, $0.01 par value, outstanding was 74,983,587 shares.

Documents Incorporated by Reference
Portions of the registrant's Annual Report to Stockholders for the year ended December 31, 2011 and Proxy Statement for use in connection with its Annual Meeting of Stockholders to be held on April 26, 2012, to be filed with the Securities and Exchange Commission pursuant to Regulation 14A not later than 120 days after December 31, 2011, are incorporated by reference in Part I (Items 1, 1A, 1B, 2, 3 and 4), Part II (Items 5, 6, 7, 7A, 8, 9, 9A and 9B), Part III (Items 10, 11, 12, 13 and 14) and Part IV (Item 15) of this Report.



AMERICAN AXLE & MANUFACTURING HOLDINGS, INC.
TABLE OF CONTENTS - ANNUAL REPORT ON FORM 10-K
 
Year Ended December 31, 2011  
 
 
 
Page Number
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 



Part I

Item 1.
Business

As used in this report, except as otherwise indicated in information incorporated by reference, references to “our Company,” "we," "our," "us" or “AAM” mean American Axle & Manufacturing Holdings, Inc. (Holdings) and its subsidiaries and predecessors, collectively.

(a)
General Development of Business

Holdings, a Delaware corporation, is a successor to American Axle & Manufacturing of Michigan, Inc., a Michigan corporation, pursuant to a migratory merger between these entities in 1999.

(b)
Financial Information About Segments

See Item 8, “Financial Statements and Supplementary Data - Note 13 - Segment and Geographic Information” included in this report.

(c)
Narrative Description of Business

Company Overview

We are a Tier I supplier to the automotive industry. We manufacture, engineer, design and validate driveline and drivetrain systems and related components and chassis modules for light trucks, sport utility vehicles (SUVs), passenger cars, crossover vehicles and commercial vehicles. Driveline and drivetrain systems include components that transfer power from the transmission and deliver it to the drive wheels. Our driveline, drivetrain and related products include axles, chassis modules, driveshafts, power transfer units, transfer cases, chassis and steering components, driveheads, transmission parts and metal-formed products. In addition to locations in the United States (U.S.) (Michigan, New York, Ohio, Indiana and Pennsylvania), we also have offices or facilities in Brazil, China, Germany, India, Japan, Luxembourg, Mexico, Poland, Scotland, South Korea, Sweden and Thailand.

We are the principal supplier of driveline components to General Motors Company (GM) for its rear-wheel drive (RWD) light trucks and SUVs manufactured in North America, supplying substantially all of GM's rear axle and front four-wheel drive and all-wheel drive (4WD/AWD) axle requirements for these vehicle platforms. Sales to GM were approximately 73% of our total net sales in 2011, 75% in 2010 and 78% in 2009.

We are the sole-source supplier to GM for certain axles and other driveline products for the life of each GM vehicle program covered by a Lifetime Program Contract (LPC). Substantially all of our sales to GM are made pursuant to the LPCs. The LPCs have terms equal to the lives of the relevant vehicle programs or their respective derivatives, which typically run 5 to 7 years, and require us to remain competitive with respect to technology, design and quality.
 
We are also the principal supplier of driveline system products for Chrysler Group LLC's (Chrysler) heavy-duty Dodge Ram full-size pickup trucks (Dodge Ram program) and its derivatives. Sales to Chrysler were approximately 8% of our total net sales in 2011, 9% in 2010 and 8% in 2009. In addition to GM and Chrysler, we supply driveline systems and other related components to Volkswagen AG (Volkswagen), Audi AG (Audi), Scania AB, Mack Trucks Inc. (Mack Truck), PACCAR Inc., Nissan Motor Co., Ltd. (Nissan), Harley-Davidson Inc., Tata Motors, Ford Motor Company (Ford), Deere & Company and other original equipment manufacturers (OEMs) and Tier I supplier companies. Our net sales to customers other than GM increased to $710.0 million in 2011 as compared to $563.0 million in 2010 and $331.2 million in 2009.

We estimate our principal served market to be approximately $37 billion, based on information available at the end of 2011. Our principal served market is the global driveline market, which consists of driveline, drivetrain and related components and chassis modules for light trucks, SUVs, passenger cars, crossover vehicles and commercial vehicles.

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The following chart sets forth the percentage of total revenues attributable to our products for the periods indicated:

 
Year ended December 31,
 
2011
 
2010
 
2009
Axles and driveshafts
81
%
 
81
%
 
75
%
Drivetrain components, forged products and other
19
%
 
19
%
 
25
%
     Total
100
%
 
100
%
 
100
%

Business Strategy

We are focused on profitably growing our net sales and strengthening our balance sheet by providing exceptional value to our customers, capitalizing on our competitive strengths and continuing to diversify our customer, product, and geographic sales mix. Over the past several years, we have implemented a Restructuring, Resizing and Profit Recovery plan that allowed us to achieve a cost structure in line with current and projected levels of customer demand and market requirements. The plan has proven successful, yielding significant, permanent structural cost reductions and has allowed us to drive down our operating breakeven level. These actions positioned us to significantly improve our profitability and free cash flow performance. We expect to benefit from these actions in the future as global economic conditions and the strength of the automotive industry continue to improve.

While continuing to emphasize our track record of operational excellence, we are focused on accelerating progress on three critical business objectives: profitable sales growth, improving business diversification and strengthening our balance sheet. These critical business objectives include the following actions:

Sustaining our operational excellence and focus on cost management to deliver exceptional value to our customers and enhance profitability.

Our focus on cost management has led to sustainable structural cost reductions in AAM's fixed cost structure and reduced our operating breakeven to a U.S. Seasonally Adjusted Annual Rate of sales
(SAAR) equivalent of approximately 10 million vehicle units.

We successfully extended our stand alone UAW agreement that covers hourly associates at our Three Rivers Manufacturing Facility to ensure market competitiveness at AAM's largest U.S. facility through 2017. We also successfully negotiated a collective bargaining agreement that covers our hourly associates at our Colfor Manufacturing subsidiary through 2014.

Advancing the diversification and innovation of our product portfolio to increase our total global served market.

We have invested over $1 billion in research and development since 1994, resulting in the development of products with industry leading technology for driveline and drivetrain systems and related components for light trucks, SUVs, passenger cars, crossover vehicles and commercial vehicles.

We have accelerated the development and launch of products for passenger cars and crossover vehicles and the global light truck and commercial vehicle markets. We have approximately $1.1 billion of new business backlog launching from 2012 to 2014, of which approximately two-thirds relates to AWD and RWD applications for passenger cars, crossover vehicles and driveline applications for the commercial vehicle market.

In 2010, we entered into a joint venture with Saab Automobile AB (Saab). The new company, e-AAM Driveline Systems AB (e-AAM), will design and commercialize electric all-wheel-drive (eAWD) systems designed to improve fuel efficiency up to 30 percent, reduce CO2 emissions and provide all-wheel-drive capability. e-AAM engineers and develops eAWD hybrid driveline systems for passenger cars and crossover vehicles that can be easily integrated into existing platforms, minimizing vehicle architecture changes.


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AAM also won an industry-first order for our EcoTrac™ disconnecting AWD technology. AAM's EcoTrac™ AWD system is a fuel-efficient and environmentally friendly driveline system that further enhances AAM's technology leadership position by providing OEMs the option of an all-wheel-drive system that disconnects when not needed to improve fuel efficiency and reduce CO2 emissions compared to conventional AWD systems. AAM's EcoTrac™ AWD system will be featured on major global passenger car and crossover vehicle programs beginning in 2013. The EcoTrac™ brand includes this AWD fuel economy optimization system, eAWD systems and a full range of high-efficiency axles.

In 2011, AAM was selected as a finalist for the 2012 Automotive News PACE Award (Premier Automotive Suppliers' Contribution to Excellence) for our industry-first cast iron to cast iron laser welding process in the manufacture of AAM's TracRite® Center Differential for Audi.  PACE awards recognize innovation in automotive suppliers' products, manufacturing processes and information technology. 

Growing new customer relationships to improve the diversification of our customer base and product portfolio.

In addition to maintaining and building upon our long standing relationships with GM and Chrysler, we have focused on generating profitable growth with new and existing global OEM customers, as well as commercial vehicle, off-road and emerging market OEMs. As a result, new business launches in 2011 through 2013 include business with Volkswagen, Audi, Nissan, Ford, Mercedes-Benz, Daimler Truck, Tata Motors, Jaguar Land Rover, Volvo Powertrain Group and Navistar.

Approximately 75% of the awards in our new business backlog launching from 2012 to 2014 are for customers other than GM. In addition, we are quoting on over $1 billion in new business opportunities to continue the diversification and expansion of our customer base, product portfolio and global footprint. Over 90% of these opportunities are for customers other than GM.

Increasing our presence in global growth markets to support our customers' global platforms and establish regional cost competitiveness.

Over the past few years, we have significantly increased our installed capacity in cost competitive global growth markets to support current and future opportunities. Specific actions include expanding facilities in Brazil, Mexico and Poland and constructing new facilities in India and Thailand.

In 2011, we also expanded our existing joint venture with Hefei Automobile Axle Co., Ltd. (HAAC), a subsidiary of the JAC Group (Anhui Jianghuai Automotive Group Co., Ltd.) to include 100% of HAAC's light commercial axle business. By adding the light and medium duty commercial axle business, this expanded joint venture will supply front and rear beam axles to several leading Chinese light truck manufacturers, including JAC and BAIC Foton, making AAM the second largest axle supplier in China 's light commercial truck segment.

Approximately 50% of our $1.1 billion of new business backlog launching from 2012 to 2014 is for end use markets outside the U.S. and approximately 70% has been sourced to our manufacturing facilities outside the U.S.

Competition and Strengths
 
We compete with a variety of independent suppliers and distributors, as well as with the in-house operations of certain OEMs. Our principal competitors include Dana Holding Corporation, GKN plc, Magna International Inc., ZF Friedrichshafen AG, Linamar Corporation, Meritor Inc. and the in-house operations of various global OEMs, such as Chrysler and Ford. The sector is also attracting new competitors from Asia, some of whom are entering both of our product lines through acquisition of OEM non-core operations.
 
With a focus on engineering and manufacturing, we support our business strategy and differentiate ourselves through the following strengths:

Outstanding long-term daily track records on quality, reliability, delivery and launch performance - We reduced our discrepant parts per million (“PPM”) performance, as measured by our largest customer, from 13,441 PPM in 1994 to less than 10 PPM currently, a level which we have sustained for the past eight years. We also have a strong track record of successfully supporting new product, process and

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facility launches.

Demonstrated ability to achieve cost savings - We reduced our operating breakeven to a U.S. SAAR equivalent of approximately 10 million vehicle units.

As a result of our 2008 labor agreements at our original U.S. locations, we converted the former fixed legacy labor cost structure to a highly flexible, competitive and variable cost structure.

We continuously evaluate the need to rationalize excess capacity through consolidation, divestiture, idling or closing facilities to maximize productivity and capacity utilization and further minimize operating and overhead costs. This is evidenced by the following actions:

Cost competitive, operationally flexible global manufacturing, engineering and sourcing footprint - We have re-aligned our global installed capacity to increase our presence in global growth markets, support global product development initiatives and establish regional cost competitiveness. This includes having manufacturing facilities in Brazil, China, India, Mexico, Poland, Thailand and the U.S.

In 2010, we idled our Salem Manufacturing Facility (part of our Colfor Manufacturing operations) and consolidated its operations within our two remaining facilities in Ohio. We also idled and consolidated certain administrative and engineering facilities in Michigan. In 2011, we closed our Spurrier Manufacturing Facility in England.

In the third quarter of 2011, we notified the International UAW of our decision to close the Cheektowaga Manufacturing Facility (CKMF) on or after February 26, 2012, the expiration of our current collective bargaining agreement with the International UAW. We had previously notified the International UAW of our decision to close the Detroit Manufacturing Complex (DMC) on or after February 26, 2012 in the second quarter of 2011. The programs currently sourced to these locations will be moved to other market cost competitive North American facilities. DMC's business will be resourced to Three Rivers Manufacturing Facility, our largest U.S. manufacturing facility, and CKMF's business will be resourced to our facilities in Ohio, Indiana and Mexico.

All of our global facilities utilize the AAM Manufacturing System, a business philosophy focused on lean manufacturing designed to facilitate cost reductions, improve quality, reduce inventory and improve our operating flexibility. This philosophy is demonstrated through the following:

Ability to drive home the benefits of market cost competitiveness and productivity initiatives - Our Three Rivers Manufacturing Facility was recently named one of the 10 best plants in North America by Industry Week Magazine, which recognizes North American manufacturing facilities that foster productive and competitive work environments and optimize customer satisfaction. The AAM Manufacturing System and associate involvement were noted as key enablers for the plant to be awarded new business.

Recognition for demonstrating outstanding achievements in manufacturing processes, quality enhancements, productivity improvement and customer satisfaction - Our Guanajuato Manufacturing Complex is a "Shingo Prize" award recipient for Manufacturing Excellence, which focuses on lean manufacturing techniques and promotes world-class business performance through continuous improvements in core manufacturing and business processes.

Industry Trends

See Item 7, “Management's Discussion and Analysis - Industry Trends.”
    
Productive Materials

We believe that we have adequate sources of supply of productive materials and components for our manufacturing needs.  Most raw materials (such as steel) and semi-processed or finished items (such as castings) are available within the geographical regions of our operating facilities from qualified sources in quantities sufficient for our needs.  We currently have contracts with our steel suppliers that ensure continuity of supply to our principal operating facilities in North America.  We also have validation and testing capabilities that enable us to strategically qualify steel sources on a global basis. As we continue to expand our global manufacturing footprint, we will need

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to rely on suppliers in local markets that have not yet proven their ability to meet our requirements. 

Research and Development (R&D)

We continue to invest in the development of new products, processes and systems to improve efficiency and flexibility in our operations and continue to deliver innovative new products, chassis modules and integrated driveline systems to our customers.

In 2011, R&D spending was $113.6 million as compared to $82.5 million in 2010 and $67.0 million in 2009. The focus of this investment continues to be developing innovative driveline and drivetrain systems and related components for light trucks, passenger cars, SUVs, crossover vehicles and commercial vehicles in the global marketplace. Product development in this area includes power transfer units, transfer cases, driveline and transmission differentials, multi-piece driveshafts, constant velocity joints, torque transfer devices, chassis modules and front and rear drive axles. We continue to focus on electronic integration in our existing and future products to advance their performance. We also continue to support the development of hybrid and electric vehicle systems. Special focus is also placed on the development of products and systems that provide our customers with efficiency, fuel economy and emissions reduction advancements. Our efforts in these areas have resulted in the development of prototypes and various configurations of these driveline systems for several OEMs throughout the world.

In 2010, we entered into a joint venture with Saab in which the new company, e-AAM, engineers and develops eAWD hybrid driveline systems to be commercialized for passenger cars and crossover vehicles. We have also developed and commercialized a disconnecting AWD system and established our new EcoTrac™ brand of fuel-efficient and environment-friendly driveline products, which strengthens AAM's position as a leader in global driveline systems technology. The EcoTrac™ brand includes the eAWD systems, the disconnecting AWD systems and a full range of high-efficiency axles. Through the development of our EcoTrac™ brand and our establishment of e-AAM, we have significantly advanced our efforts to improve fuel efficiency and ride and handling performance while reducing emissions.
 
Backlog

We typically enter into agreements with our customers to provide axles or other driveline or drivetrain products for the life of our customers' vehicle programs. Our new business backlog includes formally awarded programs and incremental content and volume including customer requested engineering changes. Our backlog may be impacted by various assumptions, many of which are provided by our customers based on their long range production plans. These assumptions include future production volume estimates, changes in program launch timing and fluctuation in foreign currency exchange rates.

Our new business backlog is approximately $1.1 billion for programs launching from 2012 to 2014. Approximately two-thirds of our new business backlog relates to RWD and AWD applications for passenger cars, crossover vehicles and driveline applications for the commercial vehicle markets. Approximately 50% of our new business backlog will be for end use markets outside the U.S. and approximately 70% of our new business backlog has been sourced to our non-U.S. manufacturing facilities. Approximately 75% of the awards in our backlog are for customers other than GM.  

Patents and Trademarks

We maintain and have pending various U.S. and foreign patents, trademarks and other rights to intellectual property relating to our business, which we believe are appropriate to protect our interest in existing products, new inventions, manufacturing processes and product developments. We do not believe that any single patent or trademark is material to our business nor would expiration or invalidity of any patent or trademark have a material adverse effect on our business or our ability to compete.

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Cyclicality and Seasonality

Our operations are cyclical because they are directly related to worldwide automotive production, which is itself cyclical and dependent on general economic conditions and other factors. Our business is also moderately seasonal as our major OEM customers historically have an extended shutdown of operations (typically 1-2 weeks) in conjunction with their model year changeover and an approximate one-week shutdown in December. Accordingly, our quarterly results may reflect these trends.

Environmental Matters

We are subject to various federal, state, local and foreign environmental and occupational safety and health laws, regulations and ordinances, including those regulating air emissions, water discharge, waste management and environmental cleanup. We closely monitor our environmental conditions to ensure that we are in compliance with applicable laws, regulations and ordinances. We have made, and will continue to make, capital and other expenditures to comply with environmental requirements, including recurring administrative costs. Such expenditures were not significant in 2011, 2010 and 2009.

Associates

We employ approximately 9,200 associates on a global basis, including our joint venture affiliates, of which approximately 3,000 are employed in the U.S. Approximately 1,625 associates are represented by the United Automobile, Aerospace and Agricultural Implement Workers of America (UAW). Approximately 335 associates represented by the UAW at our original facilities in Michigan and New York are subject to a collective bargaining agreement that expires February 25, 2012. Approximately 675 of our hourly associates at our Three Rivers Manufacturing Facility in Michigan are subject to a stand alone UAW agreement that expires September 13, 2017. An additional 615 associates at our MSP Industries Corporation and Colfor Manufacturing, Inc. subsidiaries are represented by the UAW under collective bargaining agreements that expire April 18, 2013 and June 6, 2014, respectively. In addition, approximately 115 associates at our Albion Automotive subsidiary in Scotland, approximately 2,425 associates at our Guanajuato Manufacturing Complex in Mexico and approximately 575 associates at our Araucaria Manufacturing Facility in Brazil are represented by labor unions that are subject to collective bargaining agreements. The current collective bargaining agreement at Albion will expire on March 31, 2014. The collective bargaining agreements in Mexico and Brazil expire annually.

Executive Officers of the Registrant    
Name
 
Age
 
Position
Richard E. Dauch ......................................
 
69
 
Co-Founder, Chairman of the Board & Chief Executive Officer
David C. Dauch .........................................
 
47
 
President & Chief Operating Officer
John J. Bellanti ..........................................
 
57
 
Executive Vice President - Worldwide Operations
Michael K. Simonte ...................................
 
48
 
Executive Vice President & Chief Financial Officer
Mark S. Barrett ..........................................
 
51
 
Group Vice President - Engineering, Product Development & Procurement
Alberto L. Satine .......................................
 
55
 
Group Vice President - Global Sales & Business Development
David A. Culton .........................................
 
46
 
President - AAM Europe, Vice President - AAM Corporate
Phillip R. Guys ..........................................
 
49
 
Vice President - Product Engineering
John E. Jerge ...........................................
 
50
 
President - AAM Americas, Vice President - AAM Corporate
Allan R. Monich..........................................
 
58
 
Vice President - Quality, Warranty & Customer Satisfaction
Inacio N. Moriguchi....................................
 
52
 
Vice President - Operations - AAM - Americas
Steven J. Proctor ......................................
 
55
 
President - AAM Asia, Vice President - AAM Corporate
Kevin M. Smith..........................................
 
50
 
Vice President - Driveshaft Business Unit
John S. Sofia ............................................
 
51
 
Vice President - Commercial Vehicle Business
Thomas J. Szymanski................................
 
50
 
Vice President - Global Manufacturing Services
Norman Willemse .....................................
 
55
 
Vice President - Metal Formed Product Business Unit

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Richard E. Dauch, age 69, is Co-Founder, Chairman of the Board & Chief Executive Officer of AAM, and is also Chairman of the Executive Committee of the Board of Directors. He has been Chief Executive Officer and a member of the Board of Directors since the Company began operations in March 1994. In October 1997, he was named Chairman of the Board of Directors. He was also President of AAM from March 1994 through December 2000. Prior to March 1994, he spent 12 years at the Chrysler Corporation, where he established the just-in-time materials management system and the three-shift manufacturing vehicle assembly process. He is a retired officer from the Chrysler Corporation. Mr. Dauch's last position at Chrysler, in 1991, was Executive Vice President of Worldwide Manufacturing. Mr. Dauch also served as Group Vice President of Volkswagen of America, where he established the manufacturing facilities and organization for the successful launch of the first major automotive transplant in the United States. Mr. Dauch has more than 47 years of experience in the automotive industry. Mr. Dauch was named the 1996 Worldwide Automotive Industry Leader of the Year by the Automotive Hall of Fame, the 1997 Manufacturer of the Year by the Michigan Manufacturers Association, and the 1999 Michiganian of the Year by The Detroit News. In 2003, he received the Harvard Business School of Michigan Business Statesman Award, the Ernst & Young Entrepreneur of the Year Award, and the Northwood University Outstanding Business Leader Award. In 2005, he received the Legend CEO Award from Automation Alley, and in 2006, he received the Shien-Ming Wu Foundation Manufacturing Leadership Award. Mr. Dauch also served as Chairman of the National Association of Manufacturers (N.A.M.), and currently serves on the Board of Directors of that organization. He has lectured extensively on the subject of manufacturing and authored the book, Passion for Manufacturing, which is distributed in colleges and universities globally and in several languages. Richard E. Dauch is the father of David C. Dauch.

David C. Dauch, age 47, has been President and Chief Operating Officer since June 2008. Prior to that, he served as Executive Vice President & COO (since December 2007); Executive Vice President - Commercial & Strategic Development (since January 2005); Senior Vice President, Commercial (since May 2004); Senior Vice President, Sales, Marketing & Driveline Division (since September 2003); Vice President, Manufacturing - Driveline Division (since January 2001); Vice President, Sales and Marketing (since 1998) and Director of Sales, GM Full-Size Truck Programs (since May 1996). Mr. Dauch joined our Company in July 1995 as Manager, Sales Administration. Prior to joining our Company, Mr. Dauch held various positions and served on the Board of Directors at Collins & Aikman Products Company. David C. Dauch is the son of Richard E. Dauch.

John J. Bellanti, age 57, has been Executive Vice President - Worldwide Operations since September 2008. Prior to that, he served as Group Vice President - Manufacturing Services, Capital Planning & Cost Estimating (since December 2007); Vice President - Manufacturing Services, Capital Planning & Cost Estimating (since July 2006); Vice President - Engineering & Chief Technology Officer (since May 2004); Vice President, Engineering & Product Development (since September 2003); Executive Director, Manufacturing Services (since March 2000); Director, Manufacturing Engineering (since June 1998); Director Advanced Programs (since May 1996) and Plant Manager, Detroit Forge Plant (since joining our Company in March 1994). Prior to joining our Company, Mr. Bellanti, worked 22 years at General Motors in various manufacturing and engineering positions, most recently serving as Production Manager. Mr. Bellanti was on the Board of Directors for the North American Forging Industry Association from 1999 through 2003, serving as President of that Association in 2002.

Michael K. Simonte, age 48, has been Executive Vice President & Chief Financial Officer since December 2011. Simonte previously served as Executive Vice President - Finance & Chief Financial Officer (since February 2009), Group Vice President - Finance & Chief Financial Officer (since December 2007); Vice President - Finance & Chief Financial Officer (since January 2006); Vice President & Treasurer (since May 2004); and Treasurer (since September 2002). Simonte joined AAM in December 1998 as Director, Corporate Finance. Prior to joining our Company, Mr. Simonte served as Senior Manager at the Detroit office of Ernst & Young LLP. Mr. Simonte is a certified public accountant.

Mark S. Barrett, age 51, has been Group Vice President - Engineering, Product Development & Procurement since December 2011.  Prior to that, he served as Vice President - Engineering & Product Development (since October 2008), Executive Director, Engineering & Product Development (since January 2008); Executive Director, Axle & Drivetrain (since November 2006); Executive Director, Powertrain, Driveshaft and Halfshaft Engineering (since January 2006); Executive Director, Released and Domestic Programs (since January 2004); Director, Mid Size Axle Programs (since December 1998) and Staff Project Engineer (since joining our Company in March 1994).  Prior to joining our Company, Mr. Barrett served at General Motors for nine years in a variety of manufacturing and engineering positions.   

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Alberto L. Satine, age 55, has been Group Vice President - Global Sales & Business Development since December 2011. Prior to that, he served as Vice President - Strategic & Business Development (since November 2005), Vice President - Procurement (since January 2005); Executive Director, Global Procurement Direct Materials (since January 2004); General Manager, Latin American Driveline Sales and Operations (since August 2003) and General Manager of International Operations (since joining our Company in May 2001). Prior to joining our Company, Mr. Satine held several management positions at Dana Corporation, including the position of President of Dana's Andean Operations in South America from 1997 to 2000 and General Manager of the Spicer Transmission Division in Toledo, Ohio from 1994 to 1997.

David A. Culton, age 46, has been President - AAM Europe, Vice President - AAM Corporate since November 2010. Prior to that, he served as Vice President - Commercial (since September 2009); Vice President - Unibody Vehicle Business Unit (since October 2008); Controller (since April 2007); Executive Director, Sales (since July 2006);  Director, Commercial Analysis (since August 2004); Director, Finance - Operations (Since June 2003); Finance Manager (since August 1999); and Assistant Finance Manager (since joining our Company in September 1998).  Prior to joining our Company, Mr. Culton served at Chrysler Corporation for 10 years in a variety of management, finance, engineering and manufacturing positions.

Phillip R. Guys, age 49, has been Vice President - Product Engineering since joining AAM in December 2011. Prior to joining our Company, Mr. Guys served for four years at Linamar Corporation in various senior management positions, including Vice President - Engineering, and over 20 years in various engineering positions of increasing responsibility at Ford Motor Company and General Motors.

John E. Jerge, age 50, has been President - AAM Americas, Vice President - AAM Corporate since November 2010. Prior to that, he served as Vice President - Materials, Logistics, Quality & Labor Relations (since September 2009), Vice President - Driveshaft & Halfshaft Business Unit (since October 2008); Vice President - Human Resources (since September 2004); Executive Director, Labor Relations (since April 2004); Director, Labor Relations (since January 2003); Plant Manager, Detroit Gear & Axle Plant (since March 2000); Plant Manager, Buffalo Gear Axle & Linkage (since November 1997); Manufacturing Manager, Buffalo Gear Axle & Linkage (since March 1996); Area manager of Axles and Area Manager of Linkage (since joining our Company in March 1994). Prior to joining our Company, Mr. Jerge served at Chrysler Corporation for 10 years in a variety of manufacturing, engineering and plant management positions.

Allan R. Monich, age 58, has been Vice President - Quality, Warranty & Customer Satisfaction since November 2010. Prior to that, he served as Executive Director - Warranty (since January 2010); Vice President - Quality Assurance & Customer Satisfaction (since July 2006); Vice President - Program Management & Capital Planning (since October 2005); Vice President - Program Management & Launch (since May 2004); Vice President, Manufacturing Forging Division (since October 2001); Vice President, Human Resources (since 1998); Vice President, Personnel (since November 1997) and Plant Manager for the Buffalo Gear & Axle Plant in Buffalo, NY since the formation of our Company in March 1994.  Prior to joining our Company in March 1994, Mr. Monich worked for General Motors for 22 years in the areas of manufacturing, quality assurance, sales and engineering, including four years as a Plant Manager.

Inacio N. Moriguchi, age 52, has been Vice President - Operations - AAM - Americas since November 2010. Prior to that, he served as Executive Director - AAM Manufacturing Systems (since October 2009); General Manager - Detroit Manufacturing Complex (since July 2008); President & Chief Operating Officer - Colfor Manufacturing (since July 2006); Executive Director - Manufacturing Services Metal Form Divisions (Since May 2004); Director - Manufacturing Services Forging Division (Since October 2001) and Director - Manufacturing Engineering (since October 2000). Prior to joining our Company in October 2000, Mr. Moriguchi worked for 22 years in the areas of manufacturing management, forging plant start-ups, manufacturing engineering and program launches.

Steven J. Proctor, age 55, has been President - AAM Asia, Vice President - AAM Corporate since October 2008. Prior to that, he served as Vice President - Sales & Marketing (since June 2004); Executive Director, Driveline Sales & Marketing (since September 2003); President and Chief Operating Officer of AAM do Brasil (since September 1999); Director, GMT-360, I-10/GMT-355 (since December 1998); Director, Worldwide Programs (since February 1998); Director, Strategic Planning (since July 1996) and Director, General Motors Programs (since joining our Company in March 1994). Prior to joining our Company, Mr. Proctor worked for General Motors for 20 years in the areas of product and industrial engineering, production, material management and sales.

8



Kevin M. Smith, age 50, has been Vice President - Driveshaft Business Unit since December 2011. Prior to that, he served as Vice President - Program Management & Launch (since November 2010), Executive Director - Advanced Programs, Cost Reductions & Productivity (since January 2010); Vice President - Mexico Operations (since December 2007); Plant Manager, Guanajuato Gear & Axle (since February 2007); Executive Director, Manufacturing Engineering (since July 2006); Executive Director, Axle Engineering (since January 2006); Director, GMT 900 Program (since October 2001); Director, Manufacturing Engineering (since June 2001); Plant Manager, Buffalo Gear, Axle & Linkage (since March 2000); Plant Manager, Three Rivers (since February 1998); Manufacturing Manager, Detroit Gear & Axle Plant (since February 1996) and Manufacturing Engineering Manager, Buffalo Gear, Axle & Linkage (since joining our Company in March 1994).  Prior to joining our Company, Mr. Smith served at Chrysler Corporation for 10 years in a variety of manufacturing and engineering positions.

John S. Sofia, age 51, has been Vice President - Commercial Vehicle Business since March 2008. Prior to that, he served as Vice President - Product Engineering, Commercial Vehicle Operations & Chief Technology Officer (since December 2007); Vice President - Engineering & Product Development (since July 2006); Vice President - Quality Assurance & Customer Satisfaction (since October 2004); Director, Advanced Quality Planning (since August 2002); Plant Manager, Detroit Forge (since April 2001); Director, Product Engineering (since June 2000); Manager of the Current Production & Process Engineering Group (since September 1997) and Engineering Manager (since joining our Company in May 1994). Prior to joining our Company, Mr. Sofia served at Chrysler Corporation for 10 years in a variety of manufacturing and engineering positions.

Thomas J. Szymanski, age 50, has been Vice President - Global Manufacturing Services since November 2010. Prior to that, he served as Executive Director - Manufacturing Planning (since October 2008); Executive Director - Corporate Manufacturing Services Unibody Vehicles (since January 2008); Director - Cost Estimating & Advanced Manufacturing Engineering (since August 2006); President & Chief Operating Officer - Colfor Manufacturing, Inc. (since August 2004); Director - Corporate Manufacturing Engineering (since January 2003); Plant Manager - Three Rivers Gear & Axle (since March 2000); Plant Manager - Tonawanda Forge (since December 1998); Manufacturing Manager - Tonawanda Forge (since March 1994); and Area Manager, Axle Assembly - Buffalo Gear & Axle (since the formation of our Company in March 1994). Prior to joining our Company in March 1994, Mr. Szymanski worked for General Motors for 11 years in a variety of manufacturing and plant management positions.

Norman Willemse, age 55, has been Vice President - Metal Formed Product Business Unit since December 2011. Prior to that, he served as Vice President - Global Metal Formed Product Business Unit (since October 2008), Vice President - Global Metal Formed Product Operations (since December 2007); General Manager - Metal Formed Products Division (since July 2006) and Managing Director - Albion Automotive (since joining our Company in August 2001). Prior to joining our Company, Mr. Willemse served at ATSAS for seven years as Executive Director Engineering & Commercial and John Deere for over 17 years in various engineering positions of increasing responsibility. Mr. Willemse is a professional certified mechanical engineer.

Internet Website Access to Reports

The website for American Axle & Manufacturing Holdings, Inc. is www.aam.com. Our annual reports on Form 10-K, quarterly reports on Form 10-Q, current reports on Form 8-K and amendments to those reports filed or furnished pursuant to section 13(a) or 15(d) of the Securities Exchange Act of 1934 are available free of charge through our website as soon as reasonably practicable after they are electronically filed with, or furnished to, the Securities and Exchange Commission (SEC). The SEC also maintains a website at www.sec.gov that contains reports, proxy and information statements, and other information regarding issuers that file electronically with the SEC. The information contained in the Company's website is not included, or incorporated by reference, in this annual report on Form 10-K.

9



(d)
Financial Information About Geographic Areas

International operations are subject to certain additional risks inherent in conducting business outside the U.S., such as changes in currency exchange rates, price and currency exchange controls, import restrictions, nationalization, expropriation and other governmental action. Financial information relating to our operations by geographic area is presented in the following table. Net sales are attributed to countries based upon location of customer. Long-lived assets exclude deferred income taxes.

 
December 31,
 
2011
 
2010
 
2009
 
(in millions)
Net sales
 
 
 
 
 
United States
$
1,587.3

 
$
1,396.7

 
$
979.7

Canada
60.8

 
50.1

 
66.5

Mexico
678.5

 
638.0

 
371.6

South America
134.8

 
99.5

 
34.9

Other
123.6

 
98.7

 
68.9

Total net sales
$
2,585.0

 
$
2,283.0

 
$
1,521.6

 
 
 
 
 
 
Long-lived assets
 
 
 
 
 
United States
$
845.7

 
$
816.2

 
$
818.0

Mexico
384.9

 
381.8

 
410.3

South America
131.9

 
124.4

 
112.0

Other
183.0

 
151.6

 
102.2

Total long-lived assets
$
1,545.5

 
$
1,474.0

 
$
1,442.5


10


Item 1A.
Risk Factors

The following risk factors and other information included in this Annual Report on Form 10-K should be considered. If any of the following risks occur, our business, financial condition, operating results and cash flows could be materially adversely affected.

General global economic conditions may have an adverse impact on our operating performance and results of operations.
    
The automotive industry has continued to improve over the past two years after suffering the effects of the global financial crisis we experienced in 2008 and 2009. While the U.S. SAAR increased to 12.7 million units in 2011 from 11.6 million in 2010, the automotive industry is still recovering from the effects of the unprecedented decline in consumer demand and production volumes. General economic conditions such as the depressed U.S. housing market and continued high unemployment rates may still hinder a full recovery of the domestic automotive industry over the next few years. Additionally, recent turmoil in the European credit markets and the sovereign debt crisis in the Euro-zone pose potential threats to global growth and market stability, which could have an adverse impact on the recovery of the automotive industry. Although we have reduced our operating breakeven to a SAAR equivalent of approximately 10 million vehicle units, continued weakness or deteriorating conditions in the U.S. or global economy that results in another reduction or continued depressed levels of automotive production and sales by our largest customers may adversely affect our business, financial condition and results of operations. Additionally, in a down-cycle economic environment, we may experience the negative effects of increased competitive pricing pressure and customer turnover.

Our business is significantly dependent on sales to GM and Chrysler.

We are the principal supplier of driveline components to GM for its RWD light trucks and SUVs manufactured in North America, supplying substantially all of GM's RWD and 4WD/AWD axle requirements for these vehicle platforms. Sales to GM were approximately 73% of our total net sales in 2011, 75% in 2010 and 78% in 2009. A reduction in our sales to GM or a reduction by GM of its production of RWD light trucks or SUVs, as a result of market share losses of GM or otherwise, could have a material adverse effect on our results of operations and financial condition.

We are also the principal supplier of driveline system products for Chrysler's Dodge Ram program and its derivatives. Sales to Chrysler accounted for approximately 8% of our total net sales in 2011, 9% in 2010 and 8% in 2009. A reduction in our sales to Chrysler or a reduction by Chrysler of its production of the Dodge Ram program, as a result of market share losses of Chrysler or otherwise, could have a material adverse effect on our results of operations and financial condition.

Our business is dependent on the rear-wheel drive light truck and SUV market segments in North America.
 
A substantial portion of our revenue is derived from products supporting RWD light truck and SUV platforms in North America. Sales and production levels of light trucks and SUVs are being affected by many factors, including changes in consumer demand; product mix shifts favoring other types of light vehicles, such as front-wheel drive based crossover vehicles and passenger cars; fuel prices; and government regulation, such as the corporate average fuel economy (CAFE) regulations and related emissions standards promulgated by federal and state regulators. In 2010, U.S. Congress enacted new CAFE regulations that would increase the U.S. fuel-economy standard industry average to 35 miles per gallon by year 2016, while light trucks will be required to meet nearly 28 miles per gallon by 2016. Our customers are currently reacting to these regulations, including the potential impact on consumer preferences and demand for vehicles. A reduction in the market segment we currently supply could have a material adverse impact on our results of operations and financial condition.

Our company may not realize all of the revenue expected from our new business backlog.

The realization of incremental revenues from awarded business is inherently subject to a number of risks and uncertainties, including the accuracy of customer estimates relating to the number of vehicles to be produced in new and existing product programs and the timing of such production. It is also possible that our customers may choose to delay or cancel a product program that has been awarded to us. Our revenues, operating results and financial position could be adversely affected relative to our current financial plans if we do not realize substantially

11


all the revenue from our new business backlog.

Our company or our customers may not be able to successfully launch new product programs on a timely basis.

Certain of our customers are preparing to launch new product programs for which we will supply newly developed driveline system products and related components. Some of these new product program launches have required, and will continue to require, substantial capital investment. We may not be able to install and certify the equipment needed to produce products for these new product programs in time for the start of production. There can be no assurance that we will successfully complete the transition of our manufacturing facilities and resources to support these new product programs or any other future product programs. Accordingly, the launch of new product programs may adversely affect production rates or other operational efficiency and profitability measures at our facilities. In addition, our customers may delay the launch or fail to successfully execute the launch of these product programs, or any additional future product program for which we will supply products.

We are under continuing pressure from our customers to reduce our prices.

Annual price reductions are a common practice in the automotive industry. The majority of our products are sold under long-term contracts with prices scheduled at the time the contracts are established. Many of our contracts require us to reduce our prices in subsequent years and most of our contracts allow us to adjust prices for engineering changes. If we must accommodate a customer's demand for higher annual price reductions and are unable to offset the impact of any such price reductions through continued technology improvements, cost reductions and other productivity initiatives, our results of operations and financial condition could be adversely affected.

Our business could be adversely affected by volatility in the price of raw materials.

Worldwide commodity market conditions have resulted in volatility in the cost of steel and other metallic materials in recent years. As general economic conditions and customer demand increase, the cost of such steel and metallic materials needed for our products has increased. If we are unable to pass cost increases on to our customers, this could have a material adverse effect on our results of operations and financial condition.

Our business could be adversely affected if we fail to maintain satisfactory labor relations.
 
The majority of our hourly associates worldwide are members of industrial trade unions employed under the terms of collective bargaining agreements. Substantially all of our hourly associates in the U.S. are represented by the UAW. Approximately 335 of our UAW represented associates are covered by labor agreements that expire on February 25, 2012. Approximately 3,000 of our hourly associates at our facilities in Mexico and Brazil are also covered by collective bargaining agreements which expire annually. There can be no assurance that future negotiations with our labor unions will be resolved favorably or that we will not experience a work stoppage or disruption that could have a material adverse impact on our results of operations and financial condition. In addition, there can be no assurance that such future negotiations will not result in labor cost increases or other terms and conditions that could adversely affect our results of operations and financial condition or our ability to compete for future business.

Our business could be adversely affected by disruptions in our supply chain and our customers' supply chain.

We depend on a limited number of suppliers for certain key components and materials needed for our products. We rely upon, and expect to continue to rely upon, certain suppliers for critical components and materials that are not readily available in sufficient volume from other sources. As we expand our global manufacturing footprint, we will need to rely on suppliers in local markets that have not yet proven their ability to meet our requirements. These supply chain characteristics make us susceptible to supply shortages and price increases. In addition, in recent years, several of our direct material suppliers have filed for bankruptcy protection and restructured their operations to significantly reduce their installed capacity. If production volumes increase rapidly, there can be no assurance that the suppliers of critical components and materials will be able or willing to meet our future needs on a timely basis. A significant disruption in the supply of these materials could have a material adverse effect on our results of operations and financial condition.


12


Natural disasters, such as the recent earthquake in Japan and the floods in Thailand, have affected the automotive industry's supply chain over the past year. Although our direct supply chain did not suffer any material effects from these natural disasters, future natural disasters could cause a disruption in the supply of critical components to us and our customers and have a material adverse effect on our results of operations and financial condition.

We may incur material losses and costs as a result of product recall, product liability and warranty claims, litigation and other disputes and claims.

We are exposed to warranty, product recall and product liability claims in the event that our products fail to perform as expected, and we may be required to participate in a recall of such products. Prior to 2011, we have experienced negligible warranty charges from our customers due to our contractual arrangements and the quality, warranty, reliability and durability performance of our products. As part of our 2009 Settlement and Commercial Agreement with GM, we agreed to expanded warranty cost sharing, which began on January 1, 2011. In addition, as we continue to diversify our customer base, we will also be obligated to share in the cost of providing warranties as part of our agreements with new customers. Costs and expenses associated with warranties, product recalls and product liability claims could have a material adverse impact on our results of operations and financial condition and may differ materially from the estimated liabilities that we have recorded in our consolidated financial statements.

We are also involved in various legal proceedings incidental to our business. Although we believe that none of these matters is likely to have a material adverse effect on our results of operations or financial condition, there can be no assurance as to the ultimate outcome of any such legal proceeding or any future legal proceedings.

Our company's global operations are subject to risks and uncertainties.
 
We have business and technical offices and manufacturing facilities in many foreign countries, including Brazil, China, India, Mexico, Poland, Sweden, Thailand and the U.K. Approximately 6,200 of our 9,200 associates are located outside of the U.S. International operations are subject to certain risks inherent in conducting business outside the U.S., such as changes in currency exchange rates, tax laws, price and currency exchange controls, import restrictions, nationalization, expropriation and other governmental action. Our global operations may also be adversely affected by political events and domestic or international terrorist events and hostilities. These uncertainties could have a material adverse effect on the continuity of our business and our results of operations and financial condition. As we continue to expand our business globally, our success will depend, in part, on our ability to anticipate and effectively manage these and other risks.

Our financial condition and operations may be adversely affected by a violation of financial and other covenants.

Our Revolving Credit Facility, as amended, contains financial covenants related to secured indebtedness leverage and interest coverage.  The Revolving Credit Facility and our 9.25% Senior Secured Notes due 2017 (9.25% Notes) impose limitations on our ability to make certain investments, loans and guarantees, declare dividends or distributions on capital stock, redeem or repurchase capital stock and certain debt obligations, incur liens, incur indebtedness, enter into certain restrictive agreements, merge, make acquisitions or sell all or substantially all of our assets.  The Revolving Credit Facility and the 9.25% Notes also significantly restrict our ability to incur additional secured debt.  The Revolving Credit Facility, 9.25% Notes and the indentures governing our senior unsecured notes also include customary events of default.  Obligations under the Revolving Credit Facility, the 9.25% Notes and our 7.75% senior unsecured notes are required to be guaranteed by most of our U.S. subsidiaries that hold domestic assets.  In addition, the Revolving Credit Facility and the 9.25% Notes are secured on a first priority basis by all or substantially all of our assets, the assets of Holdings and each guarantor's assets, including a pledge of capital stock of our U.S. subsidiaries that hold domestic assets and a portion of the capital stock of the first tier foreign subsidiaries of AAM and each guarantor.  A violation of any of these covenants or agreements could result in a default under these contracts, which could permit the lenders or note holders to accelerate repayment of any borrowings or notes outstanding at that time and levy on the collateral granted in connection with these contracts.  A default or acceleration under the Revolving Credit Facility, 9.25% Notes or the indentures governing our senior unsecured notes may result in increased capital costs and defaults under our other debt agreements and may adversely affect our ability to operate our business, our subsidiaries and guarantors' ability to operate their respective businesses and our results of operations and financial condition.


13




Our business faces substantial competition.
 
The automotive industry is highly competitive. Our competitors include the driveline component manufacturing facilities controlled by certain existing OEMs, as well as many other domestic and foreign companies possessing the capability to produce some or all of the products we supply. Some of our competitors are affiliated with OEMs and others have economic advantages as compared to our business, such as patents, existing underutilized capacity and lower wage and benefit costs. Technology, design, quality, delivery and cost are the primary elements of competition in our industry segment. As a result of these competitive pressures and other industry trends, OEMs and suppliers are developing strategies to reduce costs. These strategies include supply base consolidation and global sourcing. Our business may be adversely affected by increased competition from suppliers benefiting from OEM affiliate relationships, bankruptcy reorganization or financial and other resources that we do not possess. Our business may also be adversely affected if we do not sustain our ability to meet customer requirements relative to technology, design, quality, delivery and cost.

We may be unable to consummate and successfully integrate acquisitions and joint ventures.

As we continue to expand globally, we have, and may continue to, engage in acquisitions and joint ventures that involve potential risks, including failure to successfully integrate and realize the expected benefits of such acquisitions and joint ventures. Integrating acquired operations is a significant challenge and there is no assurance that we will be able to manage the integrations successfully. Failure to successfully integrate acquired operations or to realize the expected benefits of such acquisitions may have an adverse impact on our results of operations and financial condition.

Our business could be adversely affected by the cyclical nature of the automotive industry.

Our operations are cyclical because they are directly related to worldwide automotive production, which is itself cyclical and dependent on general economic conditions and other factors, such as credit availability, interest rates, fuel prices and consumer confidence. Our business may be further adversely affected by another economic decline that results in a further reduction of automotive production and sales by our largest customers. Our business may also be adversely affected by reduced demand for the product programs we currently support, or if we do not obtain sales orders for new or redesigned products that replace our current product programs.

Our company faces substantial pension and other postretirement benefit obligations.
 
We have significant pension and other postretirement benefit obligations to certain of our associates and retirees. Our ability to satisfy the funding requirements associated with these obligations will depend on our cash flow from operations and our ability to access credit and the capital markets. The funding requirements of these benefit plans, and the related expense reflected in our financial statements, are affected by several factors that are subject to an inherent degree of uncertainty and volatility, including governmental regulation. Key assumptions used to value these benefit obligations and the cost of providing such benefits, funding requirements and expense recognition include the discount rate, the expected long-term rate of return on pension assets and the health care cost trend rate. If the actual trends in these factors are less favorable than our assumptions, this could have an adverse effect on our results of operations and financial condition.

Our business is subject to costs associated with environmental, health and safety regulations.

Our operations are subject to various federal, state, local and foreign laws and regulations governing, among other things, emissions to air, discharge to waters and the generation, handling, storage, transportation, treatment and disposal of waste and other materials. We believe that our operations and facilities have been and are being operated in compliance, in all material respects, with such laws and regulations, many of which provide for substantial fines and criminal sanctions for violations. The operation of our manufacturing facilities entails risks in these areas, however, and there can be no assurance that we will not incur material costs or liabilities. In addition, potentially significant expenditures could be required in order to comply with evolving environmental, health and safety laws, regulations or other pertinent requirements that may be adopted or imposed in the future by governmental authorities.



14



Our company's ability to operate effectively could be impaired if we lose key personnel.

Our success depends, in part, on the efforts of our executive officers and other key associates. In addition, our future success will depend on, among other factors, our ability to continue to attract and retain qualified personnel. The loss of the services of our executive officers or other key associates, or the failure to attract or retain associates, could have a material adverse effect on our results of operations and financial condition.

Item 1B.
Unresolved Staff Comments

None.


15


Item 2.
Properties

We operate in 13 countries and have 34 manufacturing, engineering and business office facilities worldwide of which the principal facilities are:
Name
 
Type of
Interest
 
Function
Detroit Manufacturing Complex
Detroit, MI
 
Owned
 
Rear and front axles and steering linkages
Three Rivers Manufacturing Facility
Three Rivers, MI
 
Owned
 
Rear axles and driveshafts, front auxiliary driveshafts, universal joints and driveheads
Cheektowaga Manufacturing Facility
Cheektowaga, NY
 
Owned
 
Forged and machined products
Colfor Manufacturing, Inc.
Malvern, OH
Minerva, OH
 

Owned
Owned
 
Forged products
Forged and machined products and rear axles
MSP Industries
Oxford, MI
 
Leased
 
Forged and machined products
Oxford Forge
Oxford, MI
 
Owned
 
Forged products
DieTronik
       Auburn Hills, MI
 
Owned
 
Tool & die manufacturer
AccuGear, Inc.
       Fort Wayne, IN
 
Owned
 
Forged and machined products
Lancaster Manufacturing Facility
       Lancaster, Pennsylvania
 
Leased
 
Assembly of axles for commercial vehicles
Guanajuato Manufacturing Complex
Guanajuato, Mexico
 
Owned
 
Rear axles and driveshafts, front axles, front auxiliary driveshafts, forging products, rear differential modules and power transfer units
Araucária Manufacturing Facility
Araucária, Brazil
 
Owned
 
Front and rear axles, machining of forged and cast products, and constant velocity joints
Albion Automotive
Glasgow, Scotland
 
Leased
 
Front and rear axles for medium and heavy-duty trucks and buses
Changshu Manufacturing Facility
Changshu, China
 
Owned
 
Rear axles, gear sets and machined cases
Pantnagar Manufacturing Facility
      Pantnagar, India
 
Owned
 
Rear axles
Pune Manufacturing Facility
      Pune, India
 
Owned
 
Driveheads
Rayong Manufacturing Facility
      Rayong, Thailand
 
Owned
 
Front and rear axles and driveshafts
Swidnica Manufacturing Facility
       Swidnica, Poland
 
Owned
 
Transmission differentials and machined products
World Headquarters
Detroit, MI
 
Owned
 
Executive and administrative offices
Technical Center
      Rochester Hills, MI
 
Owned
 
R&D, design engineering, metallurgy, testing and validation

We believe that our property and equipment is properly maintained and in good operating condition. We will continue to evaluate capacity requirements in light of current and projected market conditions. We also intend to continue redeploying assets in order to increase our capacity utilization and reduce future capital expenditures to support program launches.


16


Item 3.
Legal Proceedings

We are involved in various legal proceedings incidental to our business. Although the outcome of these matters cannot be predicted with certainty, we do not believe that any of these matters, individually or in the aggregate, will

17


have a material effect on our financial condition, results of operations or cash flows.

We are subject to various federal, state, local and foreign environmental and occupational safety and health laws, regulations and ordinances, including those regulating air emissions, water discharge, waste management and environmental cleanup. We closely monitor our environmental conditions to ensure that we are in compliance with applicable laws, regulations and ordinances. We have made, and will continue to make, capital and other expenditures to comply with environmental requirements, including recurring administrative costs. Such expenditures were not significant in 2011, 2010 and 2009.

Item 4. Mine Safety Disclosures
    
Not applicable.

Part II

Item 5. Market for Registrant's Common Equity, Related Stockholder Matters and Issuer Purchases of Equity Securities

Market Information
        
Our common stock, par value $0.01 per share, is listed for trading on the New York Stock Exchange (NYSE) under the symbol “AXL.”
        
Stockholders and High and Low Sales Prices

2011
1st  Quarter
 
2nd  Quarter
 
3rd  Quarter
 
4th  Quarter
 
Full Year
 
High
$
16.15

 
$
12.80

 
$
11.96

 
$
10.04

 
$
16.15

 
Low
$
12.38

 
$
9.79

 
$
6.98

 
$
7.01

 
$
6.98

2010
 
 
 
 
 
 
 
 
 
 
High
$
11.28

 
$
11.79

 
$
10.37

 
$
13.27

 
$
13.27

 
Low
$
8.42

 
$
7.33

 
$
6.96

 
$
8.58

 
$
6.96


Prices are the quarterly high and low closing sales prices for our common stock as reported by the NYSE. We had approximately 378 stockholders of record as of February 6, 2012.

Dividends

We did not declare or pay any cash dividends on our common stock in 2011. Our debt agreements limit our ability to declare or pay dividends or distributions on capital stock.

Securities Authorized for Issuance under Equity Compensation Plans

There are no securities authorized for issuance under equity compensation plans since the Restated 1999 American Axle & Manufacturing Holdings, Inc. Stock Incentive Compensation Plan expired on January 8, 2009.

18


Item 6. Selected Financial Data

FIVE YEAR FINANCIAL SUMMARY
Year Ended December 31,

 
2011
 
2010
 
2009
 
2008
 
2007
 
 
(in millions, except per share data)
 
Statement of operations data
 
 
 
 
 
 
 
 
 
 
Net sales
$
2,585.0

 
$
2,283.0

 
$
1,521.6

 
$
2,109.2

 
$
3,248.2

 
Gross profit (loss)
455.1

 
401.7

 
(31.1
)
 
(865.2
)
 
278.4

 
Selling, general and
 
 
 
 
 
 
 
 
 
 
   administrative expenses
231.7

 
197.6

 
172.7

 
185.4

 
202.8

 
Operating income (loss)
223.4

 
204.1

 
(203.8
)
 
(1,050.6
)
 
75.6

 
Net interest expense
(82.7
)
 
(85.2
)
 
(82.5
)
 
(67.9
)
 
(52.3
)
 
Net income (loss)
137.1

(a)(b) 
114.5

 
(253.3
)
(a)(b) 
(1,224.6
)
(a) 
37.0

(a)(b) 
Net income (loss) attributable to AAM
142.8

(a)(b) 
115.4

 
(253.1
)
(a)(b) 
(1,224.3
)
(a) 
37.0

(a)(b) 
Diluted earnings (loss) per share
$
1.89

 
$
1.55

 
$
(4.81
)
 
$
(23.73
)
 
$
0.69

 
Diluted shares outstanding
75.4

 
74.5

 
52.6

 
51.6

 
53.8

 
 
 
 
 
 
 
 
 
 
 
 
Balance sheet data
 
 
 
 
 
 
 
 
 
 
Cash and cash equivalents
$
169.2

 
$
244.6

 
$
178.1

 
$
198.8

 
$
343.6

 
Total assets
2,328.7

 
2,114.7

 
1,986.8

 
2,247.7

 
3,135.9

 
Total long-term debt
1,180.2

 
1,010.0

 
1,071.4

 
1,139.9

 
858.1

 
Total AAM stockholders' equity (deficit)
(425.5
)
 
(479.5
)
 
(560.2
)
 
(435.7
)
 
899.4

 
Dividends declared per share

 

 

 
0.34

 
0.60

 
 
 
 
 
 
 
 
 
 
 
 
Statement of cash flows data
 
 
 
 
 
 
 
 
 
 
Cash provided by (used in) operating
   activities
$
(56.3
)
 
$
240.3

 
$
15.9

 
$
(163.1
)
 
$
367.9

 
Cash used in investing activities
(184.1
)
 
(107.0
)
 
(74.6
)
 
(231.7
)
 
(186.5
)
 
Cash provided by (used in) financing
   activities
167.2

 
(66.4
)
 
32.1

 
254.5

 
148.3

 
Dividends paid

 

 

 
(18.3
)
 
(31.8
)
 
 
 
 
 
 
 
 
 
 
 
 
Other data
 
 
 
 
 
 
 
 
 
 
Depreciation and amortization
$
139.4

 
$
131.6

 
$
134.7

 
$
199.5

 
$
229.4

 
Capital expenditures
163.1

 
108.3

 
137.7

 
147.3

 
186.5

 
Purchase buyouts of leased equipment
13.4

 
7.8

 

 

 

 

(a)
Includes special charges, asset impairments, and other non-recurring costs and tax refunds of $16.6 million in 2011 (including $0.5 million related to the non-controlling interest portion of a $1.6 million asset impairment recorded by e-AAM), $120.5 million in 2009, $985.4 million in 2008 and $58.7 million in 2007 primarily related to restructuring actions.

(b)
Includes charges of $3.1 million in 2011, $7.7 million in 2009 and $3.5 million in 2007, net of tax, related to debt refinancing and redemption costs.


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Item 7. Management's Discussion and Analysis of Financial Condition and Results of Operations

COMPANY OVERVIEW

American Axle & Manufacturing Holdings, Inc. (Holdings) and its subsidiaries (collectively, we, our, us or AAM) is a Tier I supplier to the automotive industry. We manufacture, engineer, design and validate driveline and drivetrain systems and related components and chassis modules for light trucks, sport utility vehicles (SUVs), passenger cars, crossover vehicles and commercial vehicles. Driveline and drivetrain systems include components that transfer power from the transmission and deliver it to the drive wheels. Our driveline, drivetrain and related products include axles, chassis modules, driveshafts, power transfer units, transfer cases, chassis and steering components, driveheads, transmission parts and metal-formed products. In addition to locations in the United States (U.S.) (Michigan, New York, Ohio, Indiana and Pennsylvania), we also have offices or facilities in Brazil, China, Germany, India, Japan, Luxembourg, Mexico, Poland, Scotland, South Korea, Sweden and Thailand.

We are the principal supplier of driveline components to General Motors Company (GM) for its rear-wheel drive (RWD) light trucks and SUVs manufactured in North America, supplying substantially all of GM's rear axle and front four-wheel drive and all-wheel drive (4WD/AWD) axle requirements for these vehicle platforms. Sales to GM were approximately 73% of our total net sales in 2011, 75% in 2010 and 78% in 2009.
 
We are the sole-source supplier to GM for certain axles and other driveline products for the life of each GM vehicle program covered by a Lifetime Program Contract (LPC). Substantially all of our sales to GM are made pursuant to the LPCs. The LPCs have terms equal to the lives of the relevant vehicle programs or their respective derivatives, which typically run 5 to 7 years, and require us to remain competitive with respect to technology, design and quality.

We are also the principal supplier of driveline system products for the Chrysler Group LLC's (Chrysler) heavy-duty Dodge Ram full-size pickup trucks (Dodge Ram program) and its derivatives. Sales to Chrysler were approximately 8% of our total net sales in 2011, 9% in 2010 and 8% in 2009. In addition to GM and Chrysler, we supply driveline systems and other related components to Volkswagen AG, Audi AG, Scania AB, Mack Trucks Inc., PACCAR Inc., Nissan Motor Co. Ltd., Harley-Davidson Inc., Tata Motors, Ford Motor Company, Deere & Company and other original equipment manufacturers (OEMs) and Tier I supplier companies. Our net sales to customers other than GM increased to $710.0 million in 2011 as compared to $563.0 million in 2010 and $331.2 million in 2009.

In 2011, we took further actions in order to improve the market cost competitiveness of our labor cost structure and rationalize our operating capacity. We notified the International UAW of our decision to close both the Detroit Manufacturing Complex (DMC) and the Cheektowaga Manufacturing Facility (CKMF) on or after February 26, 2012, the expiration of our current collective bargaining agreement with the International UAW. As a result of these recent actions, along with others made over the past several years, we have aligned our global capacity with projected market demand and improved our regional cost competitiveness on a global basis. Throughout 2011, we demonstrated our ability to operate profitably under our lower cost structure and operating breakeven level. As we look beyond 2011, we are focused on profitably growing sales, significantly diversifying our customer, product and geographic sales mix and strengthening our balance sheet.

INDUSTRY TRENDS

There are a number of significant trends affecting the highly competitive automotive industry. As general economic and industry specific conditions continue to stabilize and improve, the global automotive industry continues to experience intense competition, volatile fuel, steel, metallic and other commodity prices and significant pricing pressures. At the same time, the industry is focused on investing in future products that will incorporate the latest technology, meet changing customer demands and comply with more stringent government regulations.

In 2011, the U.S. SAAR increased to 12.7 million units from 11.6 million in 2010. While the increase in production levels represents a significant year-over-year improvement, these production levels remain depressed in comparison to the 16.1 million SAAR experienced in 2007. Although it is expected that U.S. automotive production will continue to increase in 2012 and U.S. domestic OEM market share should remain stable, it is likely that domestic production levels will remain at relatively low levels until general economic conditions significantly improve. Factors such as the depressed U.S. housing market and continued high unemployment rates may still hinder a full recovery of the domestic automotive industry over the next few years. Additionally, recent turmoil in the

20


European credit markets and the sovereign debt crisis in the euro-zone pose potential constraints to market stability and global growth in the automotive industry. However, as a result of the significant restructuring actions that were implemented over the previous years, we expect that the U.S. domestic OEMs and their suppliers will continue to capitalize on these increased volumes and provide improved financial performance as the industry gradually recovers.
 
GLOBAL AUTOMOTIVE PRODUCTION The trend toward the globalization of automotive production continues to intensify in regions such as Asia (particularly China, India, South Korea and Thailand), Eastern Europe and South America. Automotive production in these regions is expected to continue to grow while production in the traditional automotive production centers such as North America, Western Europe and Japan are continuing to improve from recent declines. We have significantly increased our global installed capacity to support current and future opportunities while reducing our installed capacity in the U.S. We have expanded our facilities in Mexico, Brazil and Poland, constructed a new facility in Thailand, increased our investment in our China joint venture and are currently constructing a new facility in India. We also have offices in Germany, India, China, South Korea, Brazil and Sweden to support these developing markets. We expect our business activity in these markets to increase significantly over the next several years. Approximately 50% of our new business backlog is for end use markets outside the U.S. and approximately 70% has been sourced to our manufacturing facilities outside the U.S.

STEEL AND OTHER METALLIC COMMODITIES Worldwide commodity market conditions have resulted in volatile steel and other metallic material prices. As general economic conditions have improved and production levels increased in 2011, demand for these commodities has grown and prices have risen. We have taken actions to mitigate the impact of this trend through commercial agreements with our customers, strategic sourcing arrangements with suppliers and technology advancements that result in using less metallic content or less expensive metallic content in the manufacturing of our products. The majority of our sales contracts with our largest customers provide price adjustment provisions for metal market price fluctuations. We do not have metal market price provisions with all of our customers for all of the parts that we sell. We also have agreed to share in the risk of metal market price fluctuations in certain customer contracts. As a result, we may experience higher net costs for raw materials. These cost increases would come in the form of metal market adjustments and base price increases. We currently have contracts with our steel suppliers that ensure continuity of supply to our principal operating facilities in North America.  We also have validation and testing capabilities that enable us to strategically qualify steel sources on a global basis.

INCREASE IN DEMAND FOR ALTERNATIVE ENERGY SOURCES AND ELECTRONIC INTEGRATION With a shift towards aggressive, environmentally focused legislation in the U.S., we have observed an increased demand for technologies designed to help reduce emissions, increase fuel economy and minimize the environmental impact of vehicles. In 2010, the U.S. Congress enacted new corporate average fuel economy (CAFE) regulations that would increase the U.S. fuel-economy standard industry average for passenger cars to 35 miles per gallon by year 2016, while light trucks will be required to meet nearly 28 miles per gallon by 2016. As a result, OEMs and suppliers are competing intensely to develop and market new and alternative technologies, such as electric vehicles, hybrid vehicles, fuel cells, diesel engines and efficiency improvements of driveline systems to improve fuel economy and emissions.

The electronic content of vehicles continues to expand, largely driven by consumer demand for greater vehicle performance, functionality, and affordable convenience options. This demand is a result of increased communication abilities in vehicles as well as increasingly stringent regulatory standards for energy efficiency, emissions reduction and increased safety. As these electronics continue to become more reliable and affordable, we expect this trend to continue. The increased use of electronics provides greater flexibility in vehicles and enables the OEMs to better control vehicle stability, fuel efficiency, and safety while improving the overall driving experience. Suppliers with enhanced capability in electronic integration have greater sourcing opportunities with OEMs and may be able to obtain more favorable pricing for these products.

We are responding to the continuing change in vehicle mix in the North American market as well as expected increases in CAFE regulations, with ongoing research and development (R&D) efforts that focus on fuel economy, emission reduction and environmental improvements. These efforts position us to compete as this product mix shift continues and have led to new business awards for products that support AWD and RWD passenger cars and crossover vehicles. We are continuing to invest in the development of advanced products focused on fuel economy, mass reductions, vehicle safety and performance leveraging electronics and technology. We have increased our focus on alternative energy and electronics by investing in product development that is consistent with the expected shift in market demand. Approximately 50% of AAM's new business backlog launching from 2012

21


to 2014, which is an estimated $1.1 billion, relates to AAM's newest AWD systems for passenger cars and crossover vehicles. In 2010, we entered into a joint venture with Saab in which the new company, e-AAM, will design and commercialize electric all-wheel-drive (eAWD) hybrid driveline systems for passenger cars and crossover vehicles. We have also developed and commercialized a disconnecting AWD system and established our new EcoTrac™ brand of fuel-efficient and environment-friendly driveline products, which strengthens AAM's position as a leader in global driveline systems technology. The EcoTrac™ brand includes the eAWD systems, the disconnecting AWD systems and a full range of high-efficiency axles. Through our establishment of e-AAM and the development of our EcoTrac™ brand, we have made great progress on our focus to improve fuel efficiency and ride and handling performance while reducing emissions.

RESULTS OF OPERATIONS
 
NET SALES Net sales increased by 13% to $2,585.0 million in 2011 as compared to $2,283.0 million in 2010 and $1,521.6 million in 2009.

Our sales in 2011, as compared to 2010, reflect an increase of approximately 7.5% in production volumes for the major North American light truck and SUV programs we currently support. These increases reflect the improvement in both general economic conditions and market conditions in the automotive industry.

Our sales in 2010, as compared to 2009, reflect an increase of approximately 42% in production volumes for the North American light truck and SUV programs we currently support for GM and Chrysler.  These increases reflect the impact of the stabilization of general economic conditions, improving market conditions in the automotive industry and the adverse impact of the extended production shutdowns in 2009, which was estimated at $304.3 million.  The increase in sales also reflects the favorable impact of recent new product launches, many of which support passenger car and crossover vehicle platforms.

Our content-per-vehicle (as measured by the dollar value of our products supporting our customers' North American light truck and SUV programs) increased to $1,487 in 2011 as compared to $1,441 in 2010 and $1,403 in 2009. The increase in 2011 as compared to 2010 is primarily due to mix shifts favoring the next generation of heavy-duty trucks for GM and higher metal market pass throughs. The increase in 2010 as compared to 2009 is primarily due to higher metal market pass throughs partially offset by a change in the billing process for consigned components for the Dodge Ram program and the adverse impact in the first half of 2010 associated with timing of the launch of the next generation heavy-duty truck for GM in June 2010.

Our 4WD/AWD penetration rate was 63.0% in 2011 as compared to 64.2% in 2010 and 64.1% in 2009. We define 4WD/AWD penetration as the total number of front axles we produce divided by the total number of rear axles we produce for the vehicle programs we support.

GROSS PROFIT (LOSS) Gross profit (loss) was a profit of $455.1 million in 2011 as compared to a profit of $401.7 million in 2010 and a loss of $31.1 million in 2009. Gross margin was 17.6% in both 2011 and 2010 and negative 2.0% in 2009. The increase in gross profit in 2011 as compared to 2010 primarily reflects the positive impact of an increase in sales and productivity gains, partially offset by special charges and the impact of the implementation of certain provisions of the 2009 Settlement and Commercial Agreement with GM. These provisions were effective January 1, 2011 and, among other things, include expanded warranty cost sharing and product price-downs. The increase in gross profit and gross margin in 2010, as compared to 2009, reflects the positive impact of an increase in sales, lower special charges and the favorable impact of structural cost reductions taken in 2008 and 2009.

Gross profit in 2011 includes special charges and other non-recurring operating costs of $15.0 million, which includes $8.7 million of asset impairment charges and indirect inventory obsolescence as a result of the announced closure of CKMF and $6.3 million of other plant closure related costs. Gross profit in 2011 also includes a $6.1 million gain related to the sale of equipment that we had previously written down to its estimated fair value as a result of asset impairments.

22



Gross profit in 2010 includes the adverse impact of an arbitration ruling related to the transfer of certain production from DMC to another AAM facility for which we recorded a charge of $5.3 million for wages and benefits owed to certain UAW represented associates at the DMC. Gross profit in 2010 also includes net special charges of $1.1 million related to $8.7 million of asset impairment and related charges at our Salem Manufacturing Facility, net of $7.6 million of adjustments to previously recorded estimates for Supplemental Unemployment Benefits (SUB), idled leased assets and one-time termination benefit accruals.

The gross loss in 2009 includes the adverse impact of extended production shutdowns at GM and Chrysler, which is estimated at $95.0 million.  Gross loss in 2009 also included $166.7 million in net special charges and other non-recurring operating costs, which primarily relate to asset impairments, indirect inventory obsolescence, idled leased assets and the acceleration of Buydown Program (BDP) expense. These net special charges also include gains related to the curtailment of certain pension and other postretirement benefits (OPEB) primarily related to associates at our original U.S. locations who elected to accelerate their remaining BDP payments and terminate employment with AAM in 2009.

SELLING, GENERAL AND ADMINISTRATIVE EXPENSES (SG&A) SG&A (including R&D) was $231.7 million in 2011 as compared to $197.6 million in 2010 and $172.7 million in 2009. SG&A as a percentage of net sales was 9.0% in 2011, 8.7% in 2010 and 11.3% in 2009. The increase in SG&A in 2011 primarily reflects increased R&D spending, including costs related to e-AAM, a joint venture we formed in the fourth quarter of 2010 to develop and commercialize electric AWD hybrid driveline systems for passenger cars and crossover vehicles. The increase in SG&A in 2010 as compared to 2009 reflects increased R&D spending and higher profit sharing accruals and other incentive compensation expense due to increased profitability, partially offset by lower professional fees related to restructuring actions.  

In the third quarter of 2011, Saab Automobile AB (Saab), our partner in the e-AAM joint venture, entered a voluntary reorganization process. As a result, in the third quarter of 2011, we recorded a $1.6 million impairment charge to SG&A to write off the intangible asset associated with the long-term supply agreement with Saab acquired as part of our joint venture formation in 2010.

SG&A in 2010 included a $3.3 million write down of administrative and engineering facilities located in Detroit, Michigan. SG&A in 2009 included special charges of $2.6 million, which primarily related to salaried workforce reductions.  In addition, we incurred approximately $9.0 million of professional fees related to restructuring actions in 2009. 
        
R&D In 2011, R&D spending in product, process and systems was $113.6 million as compared to $82.5 million in 2010 and $67.0 million in 2009. The focus of this investment continues to be developing innovative driveline and drivetrain systems and components for light trucks, SUVs, passenger cars, crossover vehicles and commercial vehicles in the global marketplace. Product development in this area includes power transfer units, transfer cases, driveline and transmission differentials, multipiece driveshafts, halfshafts, torque transfer devices, and front and rear drive axles. We continue to focus on electronic integration in our existing and future products to advance their performance. We also continue to support the development of hybrid vehicle systems. Special focus is also placed on the development of products and systems that provide our customers with efficiency, fuel economy and emissions reduction advancements. Our efforts in these areas have resulted in the development of prototypes and various configurations of these driveline systems for several OEMs throughout the world. In 2010, we entered into a joint venture with Saab, e-AAM, which will develop and commercialize eAWD systems designed to improve fuel efficiency up to 30%, reduce CO2 emissions and provide all-wheel-drive capability. We also won an industry-first order for our EcoTrac™ AWD fuel economy optimization system.

OPERATING INCOME (LOSS) Operating income (loss) was income of $223.4 million in 2011 as compared to income of $204.1 million in 2010 and a loss of $203.8 million in 2009. Operating margin was 8.6% in 2011 as compared to 8.9% in 2010 and negative 13.4% in 2009. The changes in operating income and operating margin in 2011, 2010 and 2009 were due to the factors discussed in Gross Profit (Loss) and SG&A.

INTEREST EXPENSE Interest expense was $83.9 million in 2011, $89.0 million in 2010 and $84.5 million in 2009. The decrease in interest expense 2011 as compared to 2010 relates primarily to higher capitalized interest as a result of increased capital expenditures to support our significant global program launches. The increase in interest expense in 2010 as compared to 2009 primarily reflects higher interest rates and amortization of debt issuance costs in 2010 as compared to 2009.

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The weighted-average interest rate of our total debt outstanding was 8.0%, 8.1% and 7.3% during 2011, 2010 and 2009, respectively.

INVESTMENT INCOME Investment income was $1.2 million in 2011, $3.8 million in 2010 and $2.0 million in 2009. Investment income includes interest and dividends earned on cash and cash equivalents and short-term investments during the period.  Investment income includes a gain of $0.1 million and $2.3 million in 2011 and 2010, respectively, related to distributions of our short-term investments from which distributions were previously suspended. Investment income in 2009 includes a loss of $1.3 million as a result of an other-than-temporary decline in the fair value of our short-term investments.

OTHER INCOME (EXPENSE) Following are the components of Other Income (Expense) for 2011, 2010 and 2009:

Debt refinancing and redemption costs In 2011, we expensed $3.1 million of unamortized debt issuance costs, discount and prepayment premiums related to the voluntary prepayment of $42.5 million of our 9.25% Notes and the termination of our Second Lien Term Loan with GM. In 2009, we expensed $7.7 million of unamortized debt issuance costs related to the voluntary prepayment of our term loan and a portion of our Amended Revolving Credit Facility that was scheduled to become due April 2010.

Other, net Other, net, which includes the net effect of foreign exchange gains and losses and our proportionate share of earnings from equity in unconsolidated subsidiaries, was net income of $0.5 million in 2011, expense of $0.1 million in 2010 and expense of $3.1 million in 2009.

INCOME TAX EXPENSE (BENEFIT) Income tax expense (benefit) was an expense of $1.0 million in 2011 as compared to expense of $4.3 million in 2010 and a benefit of $43.8 million in 2009. Our effective income tax rate was 0.7% in 2011 as compared to 3.6% in 2010 and 14.7% in 2009.

The following is a reconciliation of our provision for income taxes to the expected amounts using statutory rates:

 
2011
 
2010
 
2009
Federal statutory
35.0
 %
 
35.0
 %
 
35.0
 %
Foreign income taxes
(34.6
)
 
(42.9
)
 
11.6

State and local
(1.2
)
 
1.6

 
0.1

Valuation allowance
(30.7
)
 
(39.3
)
 
(10.2
)
U.S. tax on unremitted foreign earnings
26.3

 
49.6

 
(33.2
)
NOL carryback refund

 

 
16.4

Other
5.9

 
(0.4
)
 
(5.0
)
Effective income tax rate
0.7
 %
 
3.6
 %
 
14.7
 %

Our income tax expense and effective tax rate in 2011 reflects the effect of recognizing a net operating loss (NOL) benefit against our taxable income in the U.S. Our income tax expense for 2011 also reflects net tax benefits of $4.5 million relating to the favorable resolution of income tax audits in the U.S. and the impacts of tax law changes in Brazil and the state of Michigan. Our current low effective tax rate is primarily the result of our valuation allowance against deferred tax assets. Sustained levels of profitability are expected to lead to a reversal of the majority of our valuation allowance, which could occur as early as the second half of 2012. See "Critical Accounting Estimates – Valuation of Deferred Tax Assets and Other Tax Liabilities" below for more detail on the impact of this reversal.

Our income tax expense and effective tax rate for 2010 reflects the effect of recognizing an NOL benefit against our taxable income in the U.S. In conjunction with the filing of our 2009 federal tax return, under provisions contained in the American Recovery and Reinvestment Act of 2009, we recorded a tax benefit of $1.4 million in 2010 attributable to the monetization of alternative minimum tax and research and development credits. We received this tax refund during the fourth quarter of 2010.

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Our income tax expense and effective tax rate for 2009 reflects the effect of recording a tax benefit of $48.8 million related to the extension of the carryback period of our 2008 NOL and recording a valuation allowance against income tax benefits on losses in the U.S. and certain foreign subsidiaries. In 2009, we also established a deferred tax liability of $118.8 million which represented the estimated tax impact of the undistributed earnings of certain foreign subsidiaries as we believed these accumulated foreign earnings in certain jurisdictions were likely to be remitted to the U.S. as dividends or intercompany loans.
 
NET LOSS ATTRIBUTABLE TO NONCONTROLLING INTERESTS Net loss attributable to noncontrolling interests was $5.7 million in 2011, $0.9 million in 2010 and $0.2 million in 2009. The increase in 2011 primarily reflects the portion of the net expenses of e-AAM that relates to noncontrolling interests, which included an impairment charge of $0.5 million in 2011 related to the write off of the Saab intangible asset. The increase in 2010 as compared to 2009 primarily reflects the portion of the net loss of e-AAM that relates to noncontrolling interests.

NET INCOME (LOSS) ATTRIBUTABLE TO AAM AND EARNINGS (LOSS) PER SHARE (EPS) Net income (loss) attributable to AAM was income of $142.8 million in 2011 as compared to income of $115.4 million in 2010 and a loss of $253.1 million in 2009. Diluted earnings (loss) was earnings of $1.89 per share in 2011 as compared to earnings of $1.55 per share in 2010 and a loss of $4.81 per share in 2009. Net Income (Loss) and EPS were primarily impacted by the factors discussed in Gross Profit (Loss), SG&A, Interest Expense, Debt Refinancing and Redemption Costs and Income Tax Expense (Benefit).

LIQUIDITY AND CAPITAL RESOURCES

Our primary liquidity needs are to fund capital expenditures, debt service obligations, employee benefit plan obligations and our working capital investments.  We believe that operating cash flow, available cash and cash equivalent balances and available committed borrowing capacity under our Amended Revolving Credit Facility will be sufficient to meet these needs.

OPERATING ACTIVITIES Net cash used in operating activities was $56.3 million in 2011 as compared to net cash provided by operating activities of $240.3 million in 2010 and net cash provided by operating activities of $15.9 million in 2009. See below for more detail on important factors related to our cash flow from operations.

Sales and production volumes Cash provided by operating activities was favorably impacted by higher profits related to an increase in sales and production activity in 2011 and 2010.  Cash flow from operations in 2009 was adversely affected by significant reductions in revenues and profits. This includes the impact of the extended production shutdowns by our largest customers in 2009, estimated at $95 million.

2009 Settlement and Commercial Agreement   In conjunction with the 2009 Settlement and Commercial Agreement with GM, we received $110.0 million in the third quarter of 2009, $79.7 million of which is classified as cash flow from operations.

As part of the 2009 Settlement and Commercial Agreement, we also agreed to expedited payment terms of “net 10 days” from GM (as compared to previously existing terms of approximately 45 days) in exchange for a 1% early payment discount. We estimated that the accelerated payment terms favorably impacted cash flow from operations by approximately $62 million in 2009 and $23 million in 2010. On June 30, 2011, we elected to terminate the expedited payment terms and transition to GM standard weekly payment terms of approximately 50 days.  As a result of the termination of these expedited payment terms in 2011, our operating cash flow was negatively impacted by approximately $190 million in the third quarter of 2011.
 
Incentive compensation payments We paid approximately $31.0 million in 2011, approximately $5.0 million in 2010 and approximately $3.0 million in 2009 related to incentive compensation as a result of our increased profitability and statutory requirements in certain jurisdictions.

Cash paid for special charges In 2011, we made cash payments of $34.6 million for special charges primarily related to asset redeployment and other costs associated with our announced plant closures of DMC and CKMF and leased assets that were permanently idled prior to 2011. We paid $46.9 million and $60.1 million related to our ongoing restructuring actions in 2010 and 2009, respectively. These cash payments primarily related to hourly and salaried workforce reductions initiated prior to 2010.  We expect to make payments of $0.9 million in 2012 related to our remaining restructuring accrual as of December 31, 2011.

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In the third quarter of 2011 we notified the International UAW of our decision to close the CKMF on or after February 26, 2012, the expiration of our current collective bargaining agreement with the International UAW. We had previously notified the International UAW of our decision to close DMC on or after February 26, 2012 in the second quarter of 2011. We incurred asset redeployment and other non-recurring operating costs of $6.7 million and $8.3 million of capital expenditures associated with the announced closure of DMC and CKMF in 2011. We expect to incur approximately $20 million of additional asset redeployment and other plant closure related costs and approximately $25 million to $30 million of additional capital expenditures associated with the completion of these plant closures in 2012. These estimates do not include costs, if any, related to the resolution of bargaining with the International UAW related to these plant closures.

In the fourth quarter of 2011, we paid $18.6 million for purchase buyouts of leased equipment, of which $13.4 million is included in the investing section of our Consolidated Statement of Cash Flows.

Pension and OPEB We contributed $52.0 million to our pension trusts in 2011, which includes $26 million of contributions that were in excess of our minimum statutory funding requirements for the 2011 calendar year, as compared to $44.0 million in 2010 and $24.9 million in 2009. This funding compares to our annual pension expense, including special and contractual termination benefits, of $14.5 million in 2011, $12.6 million in 2010 and $13.5 million in 2009. We expect our regulatory pension funding requirements in 2012 to be approximately $35 million.

Our cash outlay for OPEB, net of GM cost sharing, was $11.5 million in 2011, $10.4 million in 2010 and $16.1 million in 2009. This compares to our annual postretirement benefit, including curtailments and settlements, of an expense of $15.2 million in 2011, expense of $12.6 million in 2010 and a credit of $55.7 million in 2009. We expect our cash outlay for other postretirement benefit obligations in 2012, net of GM cost sharing, to be approximately $16 million.

2008 AAM-GM Agreement In 2008, we entered into an agreement with GM in connection with the resolution of the strike called by the International UAW (2008 AAM - GM Agreement) in which GM agreed to provide us with $175.0 million to support the transition of our UAW represented legacy labor at our original U.S. locations.  We received $115.0 million in 2008 and collected the remaining $60.0 million from GM in 2009.

Accounts receivable Accounts receivable at year-end 2011 were $333.3 million as compared to $146.6 million at year-end 2010 and $129.7 million at year-end 2009. The increase in our year-end 2011 accounts receivable balance primarily reflects the termination of expedited payment terms with GM and the transition to standard weekly payment terms of approximately 50 days, effective June 30, 2011. The increase in our year-end 2010 accounts receivable balance primarily reflects an increase in sales in the fourth quarter of 2010 as compared to the fourth quarter of 2009.

Inventories At year-end 2011, inventories were $177.2 million as compared to $130.3 million at year-end 2010 and $90.6 million at year-end 2009. The increase in inventory in 2011 as compared to 2010 primarily reflects increased inventory levels related to new program launches, higher production in existing programs, bank builds related to our pending DMC and CKMF plant closures and the ramp-up of production at our Rayong Manufacturing facility in Thailand. We expect to reduce inventory levels in 2012. The increase in inventory in 2010, as compared to 2009, primarily reflects higher sales and production levels, as well as increased inventory at some of our facilities due to the launch of new products.

Accounts payable At year-end 2011, accounts payable were $337.1 million as compared to $283.6 million at year-end 2010 and $200.9 million at year-end 2009. The increase in accounts payable at year-end 2011 compared to year-end 2010 primarily reflects higher production levels, higher capital expenditures and the ramp up of activity at some of our foreign locations. The increase in accounts payable at year-end 2010 compared to year-end 2009 primarily reflects an increase in production levels and a normalization of payment terms with our suppliers.

Interest paid Interest paid in 2011 was $73.1 million as compared to $61.6 million in 2010 and $80.0 million in 2009. The increase in interest paid in 2011 as compared to 2010 relates primarily to higher average outstanding borrowings during the year. The decrease in interest paid in 2010 as compared to 2009 relates to the timing of interest payments on the 9.25% Notes. The amount of accrued interest included in other accrued expenses on our Consolidated Balance Sheet was $32.0 million and $31.1 million as of December 31, 2011 and 2010, respectively.


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Accrued compensation and benefits At year-end 2011, accrued compensation and benefits was $110.6 million as compared to $115.1 million at year-end 2010 and $98.9 million at year-end 2009. The increase in accrued compensation and benefits at year-end 2010 compared to year-end 2009 primarily reflected higher profit sharing accruals and other incentive compensation accruals that we paid in the first quarter of 2011.

Refundable income taxes At year-end 2011, prepaid assets and other on our Consolidated Balance Sheet included refundable income taxes of $3.5 million as compared to $5.9 million at year-end 2010 and $52.7 million at year-end 2009. The decrease in refundable income taxes in 2010 as compared to 2009 was primarily due to the the collection of the $48.8 million refund we received as a result of a special carryback election which enabled us to carryback our 2008 NOL to 2003.

INVESTING ACTIVITIES Capital expenditures were $163.1 million in 2011, $108.3 million in 2010 and $137.7 million in 2009. In 2011, our capital spending primarily supported our significant global program launches in 2011 and 2012 within our new business backlog.

We expect our capital spending in 2012 to be in the range of 6.0% to 6.5% of sales (or approximately $175 million), which includes support for our significant global program launches in 2012 and 2013 within our new business backlog.

In 2010, we formed a joint venture (JV) with Saab Automobile AB (Saab), e-AAM Driveline Systems AB (e-AAM). AAM is the majority owner, owning 67% of the shares in this JV while Saab owns the remaining 33%. In connection with the formation of e-AAM, we agreed to contribute ongoing funding to cover e-AAM's business operations through 2012 that we estimated to be approximately $26 million, based on current exchange rates at that time, of which we have paid approximately $16 million in 2011 and $5 million in 2010. In the fourth quarter of 2011, Saab filed for bankruptcy and has entered into liquidation status. We are currently in the process of negotiating the purchase of Saab's shares in this JV.

In 2009, we formed a JV with Hefei Automobile Axle Co, Ltd., (HAAC), a subsidiary of the JAC Group (Anhui Jianghuai Automobile Group Co, Ltd).  In the fourth quarter or 2011, we expanded our existing JV with HAAC to include HAAC's light commercial axle business. We made an initial investment of $10.2 million in 2009 related to the formation of this JV and an additional investment of $16.5 million in 2011 related to the expansion of this JV. Each party continues to own 50 percent of the JV, which we account for under the equity method of accounting.

In 2008, certain money-market and other similar funds that we invested in temporarily suspended redemptions.  We received $6.4 million and $71.6 million of redemptions in 2010 and 2009, respectively.

FINANCING ACTIVITIES Net cash provided by financing activities was $167.2 million in 2011 as compared to net cash used in financing activities of $66.4 million in 2010 and net cash provided by financing activities of $32.1 million in 2009. Total debt outstanding was $1,180.2 million at year-end 2011, $1,010.0 million at year-end 2010 and $1,071.4 million at year-end 2009. Total debt outstanding increased by $170.2 million at year-end 2011 as compared to year-end 2010 primarily as a result of the issuance of $200.0 million of senior unsecured notes in the fourth quarter of 2011, which was partially offset by using cash flow from operations to redeem 10% of our 9.25% Notes outstanding during the second quarter of 2011. The decrease in total debt outstanding at year-end 2010 as compared to year-end 2009 was primarily due to using cash flow from operations to pay down the amount outstanding under our Revolving Credit Facility as of December 31, 2009.
                
Amended Revolving Credit Facility In the second quarter of 2011, we amended and restated the Credit Agreement dated as of January 9, 2004 (as amended and restated, the “Amended and Restated Revolving Credit Agreement” and the facility thereunder, the “Amended Revolving Credit Facility”). As of December 31, 2011, the Amended Revolving Credit Facility provided up to $86.8 million of revolving bank financing commitments through June 2013 and $235.0 million of such revolving bank financing commitments through June 30, 2016. At December 31, 2011, $293.3 million was available under the Amended Revolving Credit Facility, which reflected a reduction of $28.5 million for standby letters of credit issued against the facility.

The Amended and Restated Revolving Credit Agreement, among other things, increased the aggregate commitments by approximately $79.0 million and extended the maturity of $235.0 million of the aggregate commitments to June 30, 2016. We paid debt issuance costs of $5.9 million, $1.6 million and $14.5 million associated with the amendments and restatements of our Revolving Credit Facility in 2011, 2010 and 2009, respectively.

27



Borrowings under the Amended Revolving Credit Facility bear interest at rates based on adjusted LIBOR or an alternate base rate, plus an applicable margin. The applicable margin for LIBOR based loans for lenders who extended their maturities will be between 3.00% and 4.50%, depending upon the corporate credit ratings of the Company. The applicable margin for lenders who did not extend their maturities remained unchanged.

Under the Amended Revolving Credit Facility, we are required to comply with financial covenants related to secured indebtedness leverage, total net leverage, and cash interest expense coverage. The Amended Revolving Credit Facility limits our ability to make certain investments, declare or pay dividends or distributions on capital stock, redeem or repurchase capital stock and certain debt obligations, incur liens, incur indebtedness, or merge, make acquisitions and sell assets.

The Amended Revolving Credit Facility is secured on a first priority basis by substantially all of the assets of Holdings, AAM Inc. and each guarantor party thereto, including a pledge of all capital stock of the U.S. subsidiaries of Holdings and each guarantor and a portion of the capital stock of AAM Inc. and each guarantor's first-tier foreign subsidiaries. In addition, obligations under the Amended Revolving Credit Facility are guaranteed by Holdings and AAM Inc.'s U.S. subsidiaries, all of which are directly owned by AAM Inc.

The Amended Revolving Credit Facility provides back-up liquidity for our other credit facilities. We intend to use the availability of long-term financing under the Amended Revolving Credit Facility to refinance any current maturities related to such debt agreements that are not otherwise refinanced on a long-term basis in their local markets.

9.25% Notes In 2009, we issued $425.0 million of 9.25% senior secured notes due 2017 (9.25% Notes). The notes were issued at a discount of $5.5 million. Net proceeds from these notes were used for the repayment of certain indebtedness. In 2010 and 2009, we paid debt issuance costs of $0.3 million and $12.6 million, respectively, related to the 9.25% Notes.

In the second quarter of 2011, we elected to exercise an option to redeem 10% of our 9.25% Notes outstanding at a redemption price of 103% of the principal amount. This resulted in a principal payment of $42.5 million and a $1.3 million payment for the redemption premium, as well as a payment related to accrued interest. Upon repayment, we expensed $1.4 million for the write off of a proportional amount of unamortized debt discount and issuance costs related to this debt. We had been amortizing the debt issuance costs and debt discount over the expected life of the borrowing. We have the right to voluntarily redeem an additional 10% of our 9.25% Notes in June 2012 and another 10% twelve months thereafter.

The 9.25% Notes share the collateral package equally and ratably with the Amended Revolving Credit Facility as described above. The indenture governing the 9.25% Notes limits our ability to make certain investments, declare or pay dividends or distributions on capital stock, redeem or repurchase capital stock and certain debt obligations, incur liens, incur indebtedness, transact with affiliates or merge, make acquisitions and sell assets.

Amended Term Loan On December 18, 2009, we voluntarily prepaid the amounts outstanding under our $250.0 million Amended Term Loan. Upon repayment, we expensed $6.1 million of unamortized debt issuance costs. We had been amortizing the debt issuance costs over the expected life of the borrowing. We paid $5.8 million of debt issuance costs related to the amendment and restatement of our Term Loan in 2009.

Second Lien Term Loan Facility As part of the 2009 Settlement and Commercial Agreement with GM, we entered into certain agreements which, among other things, provided us with expedited payment terms of “net 10 days” in exchange for a 1% early payment discount and a $100.0 million Second Lien Term Loan Facility with GM through December 31, 2013.  We paid $0.3 million of debt issuance costs related to the Second Lien Term Loan Facility in 2010. Pursuant to the terms of such agreements, we elected to terminate the expedited payment terms and the Second Lien Term Loan Agreement, effective June 30, 2011. As a result of these terminations, our Access and Security Agreement with GM expired on September 28, 2011.

7.875% Notes In 2007, we issued $300.0 million of 7.875% senior unsecured notes due 2017. Net proceeds from these notes were used for general corporate purposes, including payment of amounts outstanding under our Revolving Credit Facility.

28



7.75% Notes In the fourth quarter of 2011, we issued $200.0 million of 7.75% senior unsecured notes due 2019 (7.75% Notes). Net proceeds from these notes were used for general corporate purposes, including the repayment of certain amounts outstanding under our Amended Revolving Credit Facility. In 2011, we paid debt issuance costs of $5.0 million related to the 7.75% Notes.

5.25% Notes The 5.25% Notes are senior unsecured obligations due February 2014.

2.00% Convertible Notes In 2006, the 2.00% Senior Convertible Notes due 2024 became convertible into cash under terms of the indenture. A total of $0.4 million and $2.3 million of the notes were converted into cash in 2011 and 2008, respectively. The remaining outstanding 2.00% Convertible Notes were fully redeemed in the third quarter of 2011.

Foreign credit facilities We utilize local currency credit facilities to finance the operations of certain foreign subsidiaries. At December 31, 2011, $45.2 million was outstanding under these facilities and an additional $16.0 million was available.

Credit ratings To access public debt capital markets, the Company relies on credit rating agencies to assign short-term and long-term credit ratings to our securities as an indicator of credit quality for fixed income investors. A credit rating agency may change or withdraw its ratings based on its assessment of our current and future ability to meet interest and principal repayment obligations. Credit ratings affect our cost of borrowing under our Amended Revolving Credit Facilty and may affect our access to debt capital markets and other costs to fund our business. The credit ratings and outlook currently assigned to our securities by the rating agencies, which reflect multiple upgrades during 2011, are as follows:
 
Corporate Family Rating
Senior Secured Notes Rating
Senior Unsecured Notes Rating
Outlook
Standard & Poor's
BB-
BB+
B
Stable
Moody's Investors Services
B1
Ba1
B1/B2(1)
Stable
Fitch Ratings
B+
BB+
B-
Positive

(1)
On October 31, 2011, Moody's assigned a B1 rating to AAM's new $200.0 million 7.75% senior unsecured notes and affirmed the B2 rating on existing unsecured notes.

Stock warrants As part of the 2009 Settlement and Commercial Agreement, we issued to GM five year warrants, which entitled GM to purchase 4.1 million shares of AAM's common stock at an exercise price of $2.76 per share.  In the first quarter of 2011, GM exercised these warrants. In accordance with the cashless exercise option available in the agreement, we issued 3.3 million net shares of common stock to GM. We have classified $30.3 million of the payment received from GM as part of the 2009 Settlement and Commercial Agreement as cash flow from financing activities, which represents the grant date fair value of the warrants issued to GM on September 16, 2009.

Issuance of Common Stock In 2009, we sold 16.1 million shares of AAM's common stock, par value $0.01 per share, in a public offering at a price of $7.20 per share for total net proceeds of approximately $109.7 million. Net proceeds from the sale of our common stock were used for general corporate purposes.

Dividend program In 2009, the Company's Board of Directors decided to discontinue the quarterly cash dividend. We have not declared or paid any cash dividends on our common stock in 2011, 2010 or 2009.

Stock repurchase In 2010, we repurchased 0.1 million shares of AAM common stock for $1.3 million to satisfy employee tax withholding obligations due upon the vesting of our restricted stock grants.

Exercise of employee stock options We received $4.6 million in 2011 related to the exercise of employee stock options.

29



Off-balance sheet arrangements Our off-balance sheet financing relates principally to operating leases for commercial office and production facilities, vehicles and other assets. We lease certain equipment under operating leases with various expiration dates.  Pursuant to these operating leases, we may have the option to purchase the underlying equipment on specified dates. As of December 31, 2011, we do not have any remaining lease repurchase options.

Contractual obligations The following table summarizes payments due on our contractual obligations as of December 31, 2011:
 
Payments due by period
 
Total
 
  <1yr
 
     1-3 yrs
 
    3-5 yrs
 
    >5 yrs
 
(in millions)
Long-term debt
$
1,174.0

 
$
41.3

 
$
253.7

 
$

 
$
879.0

Interest obligations
516.5

 
95.1

 
179.7

 
159.0

 
82.7

Capital lease obligations
6.2

 
0.5

 
0.7

 
0.9

 
4.1

Operating leases (1)
16.2

 
5.2

 
7.5

 
3.4

 
0.1

Purchase obligations (2) 
127.5

 
114.7

 
12.8

 

 

Other long-term liabilities (3)
598.0

 
52.9

 
125.6

 
118.8

 
300.7

Total
$
2,438.4

 
$
309.7

 
$
580.0

 
$
282.1

 
$
1,266.6


(1)
Operating leases include all lease payments through the end of the contractual lease terms, which includes elections for repurchase options and excludes any non-exercised purchase options. These commitments include commercial office and production facilities, vehicles and other assets.

(2)
Purchase obligations represent our obligated purchase commitments for capital expenditures and related project expense.

(3)
Other long-term liabilities represent our estimated pension and other postretirement benefit obligations that were actuarially determined through 2021, as well as our unrecognized income tax benefits.


30


CYCLICALITY AND SEASONALITY

Our operations are cyclical because they are directly related to worldwide automotive production, which is itself cyclical and dependent on general economic conditions and other factors. Our business is also moderately seasonal as our major OEM customers historically have an extended shutdown of operations (typically 1-2 weeks) in conjunction with their model year changeover and an approximate one-week shutdown in December. Accordingly, our quarterly results may reflect these trends.

LEGAL PROCEEDINGS

We are involved in various legal proceedings incidental to our business. Although the outcome of these matters cannot be predicted with certainty, we do not believe that any of these matters, individually or in the aggregate, will have a material effect on our financial condition, results of operations or cash flows.

We are subject to various federal, state, local and foreign environmental and occupational safety and health laws, regulations and ordinances, including those regulating air emissions, water discharge, waste management and environmental cleanup. We closely monitor our environmental conditions to ensure that we are in compliance with applicable laws, regulations and ordinances. We have made, and will continue to make, capital and other expenditures (including recurring administrative costs) to comply with environmental requirements, including recurring administrative costs. Such expenditures were not significant in 2011, 2010 and 2009.
 
EFFECT OF NEW ACCOUNTING STANDARDS

In June 2011, the FASB issued new accounting guidance on the presentation of comprehensive income. The new guidance allows an entity to present components of net income and other comprehensive income in one continuous statement, referred to as the statement of comprehensive income, or in two separate, but consecutive statements. The guidance eliminates the current option to report other comprehensive income and its components in the statement of changes in equity. While the new guidance changes the presentation of comprehensive income, there are no changes to the components that are recognized in net income or other comprehensive income under current accounting guidance. This new guidance is effective for fiscal years and interim periods beginning after December 15, 2011. Other than the change in presentation, the adoption of this new guidance will not have an impact on our consolidated financial statements.

In September 2011, the FASB issued new accounting guidance on testing goodwill for impairment. This new guidance will allow us the option to first assess qualitative factors to determine whether it is necessary to perform the two-step quantitative goodwill impairment test. Under these amendments, we would not be required to calculate the fair value of a reporting unit unless we determine, based on a qualitative assessment, that it is more likely than not that its fair value is less than its carrying amount. The amendments include a number of events and circumstances to consider in conducting the qualitative assessment. This new guidance is effective for interim and annual periods beginning after December 15, 2011 with early adoption permitted. We have not adopted this guidance as of December 31, 2011 and do not believe the adoption will have a significant effect on our goodwill impairment assessments in the future.

CRITICAL ACCOUNTING ESTIMATES

In order to prepare consolidated financial statements in conformity with accounting principles generally accepted in the United States of America (GAAP), we are required to make estimates and assumptions that affect the reported amounts and disclosures in our consolidated financial statements. These estimates are subject to an inherent degree of uncertainty and actual results could differ from our estimates.
 
Other items in our consolidated financial statements require estimation. In our judgment, they are not as critical as those disclosed below. We have discussed and reviewed our critical accounting estimates disclosure with the Audit Committee of our Board of Directors.

31



PENSION AND OTHER POSTRETIREMENT BENEFITS In calculating our assets, liabilities and expenses related to pension and OPEB, key assumptions include the discount rate, expected long-term rates of return on plan assets and rates of increase in health care costs.

The discount rates used in the valuation of our U.S. pension and OPEB obligations were based on an actuarial review of a hypothetical portfolio of long-term, high quality corporate bonds matched against the expected payment stream for each of our plans. In 2011, the weighted average discount rates determined on that basis for both the valuation of our pension benefit obligations and our OPEB obligations were 5.10%. The discount rate used in the valuation of our U.K. pension obligation was based on a review of long-term bonds, including published indices in the applicable market. In 2011, the discount rate determined on that basis was 4.65%. The expected long-term rates of return on our plan assets were 8.00% for our U.S. plans and 4.60% for our U.K. plan in 2011. We developed these rates of return assumptions based on future capital market expectations for the asset classes represented within our portfolio and a review of long-term historical returns. The asset allocation for our plans was developed in consideration of the demographics of the plan participants and expected payment stream of the liability. Our investment policy allocates approximately 50% of the plans' assets to equity securities, depending on the plan, with the remainder invested in fixed income securities, hedge fund investments and cash. The rates of increase in health care costs are based on current market conditions, inflationary expectations and historical information.

All of our assumptions were developed in consultation with our actuarial service providers. While we believe that we have selected reasonable assumptions for the valuation of our pension and OPEB obligations at year-end 2011, actual trends could result in materially different valuations.

The effect on our pension plans of a 0.5% decrease in both the discount rate and expected return on assets is shown below as of December 31, 2011, our valuation date.

 
 
 
Expected
 
Discount
 
Return on
 
Rate
 
Assets
 
(in millions)
Decline in funded status
$
48.7

 
N/A

Increase in 2011 expense
$
1.0

 
$
2.2


No changes in benefit levels and no changes in the amortization of gains or losses have been assumed.

For 2012, we assumed a weighted average annual increase in the per-capita cost of covered health care benefits of 8.5% for OPEB. The rate is assumed to decrease gradually to 5.0% by 2019 and remain at that level thereafter. A 0.5% decrease in the discount rate for our OPEB would have decreased total expense in 2011 and increased the postretirement obligation, net of GM cost sharing, at December 31, 2011 by $0.3 million and $19.6 million, respectively. A 1.0% increase in the assumed health care trend rate would have increased total service and interest cost in 2011 and the postretirement obligation, net of GM cost sharing, at December 31, 2011 by $1.7 million and $35.9 million, respectively.

As part of our 2009 Settlement and Commercial Agreement, GM confirmed its obligation to share in the cost of OPEB for eligible retirees proportionally based on the length of service an employee had with AAM and GM. We estimate the future cost sharing payments and present it as an asset on our Consolidated Balance Sheet. As of December 31, 2011, we estimated $270.6 million in future GM cost sharing. If, in the future, GM was unable to fulfill this financial obligation, our OPEB expenses may be different than our current estimates.

32



VALUATION OF DEFERRED TAX ASSETS AND OTHER TAX LIABILITIES Because we operate in many different geographic locations, including several foreign, state and local tax jurisdictions, the evaluation of our ability to use all recognized deferred tax assets is complex.

We are required to estimate whether recoverability of our deferred tax assets is more likely than not, based on forecasts of taxable income in the related tax jurisdictions. In these estimates, we use historical results, projected future operating results based upon approved business plans, eligible carryforward periods, tax planning opportunities and other relevant considerations. This includes the consideration of tax law changes, prior profitability performance and the uncertainty of future projected profitability.

As of December 31, 2011, 2010 and 2009, we had valuation allowances of $426.9 million, $560.9 million and $559.7 million, respectively. These valuation allowances mainly related to the full valuation allowances on our U.S. net deferred tax assets.

If, in the future, we generate taxable income on a sustained basis in the U.S. or in foreign jurisdictions for which we have recorded valuation allowances, our current estimate of the recoverability of our deferred tax assets could change and result in the future reversal of some or all of the valuation allowance. While we believe we have made appropriate valuations of our deferred tax assets, unforeseen changes in tax legislation, regulatory activities, audit results, operating results, financing strategies, organization structure and other related matters may result in material changes in our deferred tax asset valuation allowances or our tax liabilities.

Under applicable GAAP, a sustained period of profitability in our operations is required before we would change our judgment regarding the need for a full valuation allowance against our net deferred tax assets.  Accordingly, although we were profitable on a consolidated basis in the second half of 2009 and the full year 2010 and 2011, we continue to record a full valuation allowance against the net deferred tax assets in the U.S. and certain foreign jurisdictions.  Although the weight of negative evidence related to cumulative losses is decreasing, we believe that this objectively-measured negative evidence outweighs the subjectively-determined positive evidence (primarily forecasts of future income) and, as such, we have not changed our judgment regarding the need for a full valuation allowance in 2011.

Continued improvement in our operating results, however, could lead to reversal of substantially all of our valuation allowance as early as the second half of 2012.  Until such time, consumption of tax attributes to offset profits will reduce the overall level of deferred tax assets subject to valuation allowance.

For each reporting period until the valuation allowance is released, we expect to have low effective tax rates as we continue to record tax expense only for those locations in which we do not have a valuation allowance in place.  We expect to experience higher effective tax rates after the valuation allowance is reversed.

In the quarter in which the valuation allowance is released, we would record a significant tax benefit reflecting the release, which would result in a negative effective tax rate and have a significant favorable impact on earnings per share from net income attributable to AAM.  

To the extent our uncertain tax positions do not meet the “more likely than not” threshold, we have derecognized such positions. To the extent our uncertain tax positions meet the “more likely than not” threshold, we have measured and recorded the highest probable benefit, and have established appropriate reserves for benefits that exceed the amount likely to be defended upon examination.

As of December 31, 2011, 2010 and 2009, we have recorded a liability for unrecognized income tax benefits and related interest and penalties of $33.2 million, $69.0 million and $55.9 million, respectively. As of December 31, 2011, we have recorded deferred tax assets of $6.9 million that offset the impact of these liabilities for unrecognized income tax benefits. Our U.S. federal and certain state income tax returns and certain non-U.S. income tax returns are currently under various stages of audit by the relevant tax authorities. We will continue to monitor the progress and conclusions of all ongoing audits and will adjust our estimated liability as necessary.

33



PRODUCT WARRANTY We record a liability against cost of goods sold for estimated warranty obligations at the dates our products are sold or when specific warranty issues are identified. Liabilities for product recalls are recorded at the time the company's obligation is probable and can be reasonably estimated. Product warranties not expected to be paid within one year are recorded as a non-current liability on our Consolidated Balance Sheet. Our estimated warranty obligations for products sold are based on significant management estimates, with input from our warranty, sales, engineering, quality and legal departments. For products and customers with actual warranty payment experience, we will estimate warranty costs principally based on past claims history. For certain products and customers, actual warranty payment experience does not exist or is not mature. In these cases, we estimate our costs based on our analysis of the contractual arrangements with individual customers, existing customer warranty programs, sales history and internal and external warranty data, including a determination of our involvement in the matter giving rise to the potential warranty issue or claim and estimates of repair costs. These estimates are re-evaluated on an ongoing basis.

As part of the 2009 Settlement and Commercial Agreement, we agreed to expanded warranty cost sharing with GM starting on January 1, 2011.

We actively study trends of our warranty claims and take action to improve product quality and minimize warranty claims. Warranty accruals are evaluated and adjusted as appropriate based on occurrences giving rise to potential warranty exposure and associated experience. As of December 31, 2011, our warranty accrual was $13.4 million. Actual experience could differ from the amounts estimated requiring adjustments to these liabilities in future periods. While we have not experienced any significant differences between these estimates and our actual costs, it is possible that changes in our assumptions or future warranty issues could materially affect our financial position and results of operations.

ENVIRONMENTAL OBLIGATIONS   Due to the nature of our operations, we have legal obligations to perform asset retirement activities related to federal, state, local and foreign environmental requirements. The process of estimating environmental liabilities is complex and significant uncertainty exists related to the timing and method of the settlement of these obligations.  Therefore, these liabilities are not reasonably estimable until a triggering event occurs that allows us to estimate a range and possibilities of potential settlement dates, and the potential methods of settlement.
 
As a result of the plant closures, idling and consolidation of facilities in 2011, 2010 and 2009, the methods and timing of certain asset retirement obligations related to these facilities became reasonably estimable.  Based on management's best estimate of the costs, methods and timing of the settlement of these obligations, we recorded a charge of $0.1 million in 2011 and 2010 and $1.0 million in 2009. As of December 31, 2011, the accrual for this liability was $0.6 million. In the future, we will update our estimated costs and potential settlement dates and methods and their associated probabilities based on current information.  Any update may change our best estimate and could result in a material adjustment to this liability.

GOODWILL We review our goodwill for impairment annually during the fourth quarter. In addition, we review goodwill for impairment whenever adverse events or changes in circumstances indicate a possible impairment.   This review utilizes a two-step impairment test required by the accounting guidance covering goodwill and other indefinite-lived intangibles. The first step involves a comparison of the fair value of a reporting unit with its carrying value.  If the carrying value of the reporting unit exceeds its fair value, the second step of the process involves a measurement and comparison of the fair value of goodwill with its carrying value.  If the carrying value of the reporting unit's goodwill exceeds the fair value of that goodwill, an impairment loss is recognized in an amount equal to the excess.  

The determination of our reporting units, impairment indicators and the fair value of those reporting units and corresponding goodwill require us to make significant judgments and estimates, including the extent and timing of future cash flows. As part of the determination of future cash flows, we need to make assumptions on future general economic conditions, business projections, growth rates and discount rates. These assumptions require significant judgment and are subject to a considerable degree of uncertainty. We believe that the assumptions and estimates in our review of goodwill for impairment are reasonable. However, different assumptions could materially effect our conclusions on this matter. We performed our annual analysis in the fourth quarter and determined there was no impairment to goodwill in 2011.

34



IMPAIRMENT OF LONG-LIVED ASSETS Long-lived assets, excluding goodwill and other indefinite-lived intangible assets, to be held and used are reviewed for impairment whenever adverse events or changes in circumstances indicate a possible impairment. Recoverability of each “held for use” asset group affected by impairment indicators is determined by comparing the forecasted undiscounted cash flows of the operations to which the assets relate to their carrying amount.  If the carrying amount of an asset group exceeds the undiscounted cash flows and is therefore nonrecoverable, the assets in this group are written down to their estimated fair value.  We estimate fair value based on market prices, when available, or on a discounted cash flow analysis.  Long-lived assets held for sale are recorded at the lower of their carrying amount or fair value less cost to sell. Significant judgments and estimates used by management when evaluating long-lived assets for impairment include:
 
An assessment as to whether an adverse event or circumstance has triggered the need for an impairment review;  
Determination of asset groups, the primary asset within each group, and the primary asset's average estimated useful life;
Undiscounted future cash flows generated by the assets; and
Determination of fair value when an impairment is deemed to exist, which may require assumptions related to future general economic conditions, future expected production volumes, product pricing and cost estimates, working capital and capital investment requirements, discount rates and estimated liquidation values.
 
In 2011, we recorded asset impairment charges of $8.1 million as a result of the announced closure of CKMF. In 2010, we recorded asset impairment charges of $8.4 million as a result of the announced closure of our Salem Manufacturing Facility. We also classified certain administrative and engineering facilities located in Detroit, Michigan as held-for-sale and recorded a loss of $5.1 million to write these assets down to their estimated fair value using available market data in 2010. We recorded asset impairment charges of $147.8 million in 2009 associated with the permanent idling of certain assets and the writedown of the carrying value of certain assets that were “held for use” to their estimated fair value.

ESTIMATED USEFUL LIVES FOR DEPRECIATION   At December 31, 2011, approximately 75% of our capitalized investment in property, plant and equipment was related to productive machinery and equipment used in support of our manufacturing operations.  The selection of appropriate useful life estimates for such machinery and equipment is a critical element of our ability to properly match the cost of such assets with the operating profits and cash flow generated by their use.  We currently depreciate productive machinery and equipment on the straight-line method using composite useful life estimates up to 12 years.

While we believe that the useful life estimates currently being used for depreciation purposes reasonably approximate the period of time we will use such assets in our operations, unforeseen changes in product design and technology standards or cost, quality and delivery requirements may result in actual useful lives that differ materially from the current estimates.

35


Forward-Looking Statements

In this MD&A and elsewhere in this Annual Report, we make certain statements concerning our expectations, beliefs, plans, objectives, goals, strategies, and future events or performance. Such statements are “forward-looking” statements within the meaning of the Private Securities Litigation Reform Act of 1995 and relate to trends and events that may affect our future financial position and operating results. The terms “will,” “may,” “could,” “would,” “plan,” “believe,” “expect,” “anticipate,” “intend,” “project” and similar words or expressions are intended to identify forward-looking statements.

Forward-looking statements should not be read as a guarantee of future performance or results, and will not necessarily be accurate indications of the times at, or by, which such performance or results will be achieved. Forward-looking statements are based on information available at the time those statements are made and/or management's good faith belief as of that time with respect to future events and are subject to risks and may differ materially from those expressed in or suggested by the forward-looking statements. Important factors that could cause such differences include, but are not limited to:

global economic conditions, including the impact of the current sovereign debt crisis in the Euro-zone; 
reduced purchases of our products by GM, Chrysler or other customers;
reduced demand for our customers' products (particularly light trucks and SUVs produced by GM and Chrysler);
our ability to realize the expected revenues from our new business backlog;
our ability or our customers' and suppliers' ability to successfully launch new product programs on a timely basis;
our ability to achieve the level of cost reductions required to sustain global cost competitiveness;
our ability to attract new customers and programs for new products;
supply shortages or price increases in raw materials, utilities or other operating supplies as a result of natural disasters or otherwise;
our ability to respond to changes in technology, increased competition or pricing pressures;
price volatility in, or reduced availability of, fuel;
our ability to maintain satisfactory labor relations and avoid work stoppages;
our suppliers', our customers' and their suppliers' ability to maintain satisfactory labor relations and avoid work stoppages;
risks inherent in our international operations (including adverse changes in political stability, taxes and other law changes, potential disruption of production and supply, and currency rate fluctuations);
liabilities arising from warranty claims, product recall, product liability and legal proceedings to which we are or may become a party;
availability of financing for working capital, capital expenditures, R&D or other general corporate purposes, including our ability to comply with financial covenants;
our customers' and suppliers' availability of financing for working capital, capital expenditures, R&D or other general corporate purposes;
our ability to develop and produce new products that reflect market demand;
lower-than-anticipated market acceptance of new or existing products;
our ability to consummate and integrate acquisitions and joint ventures;
adverse changes in laws, government regulations or market conditions affecting our products or our customers' products (such as the Corporate Average Fuel Economy (“CAFE”) regulations);
changes in liabilities arising from pension and other postretirement benefit obligations;
risks of noncompliance with environmental regulations or risks of environmental issues that could result in unforeseen costs at our facilities;
our ability to attract and retain key associates;
other unanticipated events and conditions that may hinder our ability to compete.

It is not possible to foresee or identify all such factors and we make no commitment to update any forward-looking statement or to disclose any facts, events or circumstances after the date hereof that may affect the accuracy of any forward-looking statement.

36


Item 7A. Quantitative and Qualitative Disclosures about Market Risk

MARKET RISK

Our business and financial results are affected by fluctuations in world financial markets, including interest rates and currency exchange rates. Our hedging policy has been developed to manage these risks to an acceptable level based on management's judgment of the appropriate trade-off between risk, opportunity and cost. We do not hold financial instruments for trading or speculative purposes.

CURRENCY EXCHANGE RISK From time to time, we use foreign currency forward contracts to reduce the effects of fluctuations in exchange rates, primarily relating to the Mexican Peso, Euro, Pound Sterling and Brazilian Real. At December 31, 2011, we had currency forward contracts relating to the Mexican Peso with a notional amount of $68.6 million outstanding.  The potential decrease in fair value of foreign exchange contracts, assuming a 10% adverse change in the foreign currency exchange rates, would be approximately $6.2 million at December 31, 2011.

Future business operations and opportunities, including the expansion of our business outside North America, may further increase the risk that cash flows resulting from these activities may be adversely affected by changes in currency exchange rates. If and when appropriate, we intend to manage these risks by utilizing local currency funding of these expansions and various types of foreign exchange contracts.

INTEREST RATE RISK We are exposed to variable interest rates on certain credit facilities. From time to time, we have used interest rate hedging to reduce the effects of fluctuations in market interest rates. As of December 31, 2011, there are no interest rate swaps in place. The pre-tax earnings and cash flow impact of a one-percentage-point increase in interest rates (approximately 13% of our weighted-average interest rate at December 31, 2011) on our long-term debt outstanding at December 31, 2011 would be approximately $0.4 million on an annualized basis.


37

AMERICAN AXLE & MANUFACTURING HOLDINGS, INC.

Item 8.
Financial Statements and Supplementary Data

Consolidated Statements of Operations
Year Ended December 31,
 
2011
 
2010
 
2009
 
(in millions, except per share data)
 
 
 
 
 
 
Net sales
$
2,585.0

 
$
2,283.0

 
$
1,521.6

 
 
 
 
 
 
Cost of goods sold
2,129.9

 
1,881.3

 
1,552.7

 
 
 
 
 
 
Gross profit (loss)
455.1

 
401.7

 
(31.1
)
 
 
 
 
 
 
Selling, general and administrative expenses
231.7

 
197.6

 
172.7

 
 
 
 
 
 
Operating income (loss)
223.4

 
204.1

 
(203.8
)
 
 
 
 
 
 
Interest expense
(83.9
)
 
(89.0
)
 
(84.5
)
 
 
 
 
 
 
Investment income
1.2

 
3.8

 
2.0

 
 
 
 
 
 
Other income (expense)
 
 
 
 
 
Debt refinancing and redemption costs
(3.1
)
 

 
(7.7
)
Other, net
0.5

 
(0.1
)
 
(3.1
)
 
 
 
 
 
 
Income (loss) before income taxes
138.1

 
118.8

 
(297.1
)
 
 
 
 
 
 
Income tax expense (benefit)
1.0

 
4.3

 
(43.8
)
 
 
 
 
 
 
Net income (loss)
$
137.1

 
$
114.5

 
$
(253.3
)
 
 
 
 
 
 
Net loss attributable to noncontrolling interests
5.7

 
0.9

 
0.2

 
 
 
 
 
 
Net income (loss) attributable to AAM
$
142.8

 
$
115.4

 
$
(253.1
)
 
 
 
 
 
 
Basic earnings (loss) per share
$
1.91

 
$
1.61

 
$
(4.81
)
 
 
 
 
 
 
Diluted earnings (loss) per share
$
1.89

 
$
1.55

 
$
(4.81
)
 
 
 
 
 
 

See accompanying notes to consolidated financial statements


38

AMERICAN AXLE & MANUFACTURING HOLDINGS, INC.

Consolidated Balance Sheets
December 31,
 
2011
 
2010
Assets
(in millions, except per share data)
Current assets
 
 
 
   Cash and cash equivalents
$
169.2

 
$
244.6

   Accounts receivable, net
333.3

 
146.6

   Inventories, net
177.2

 
130.3

   Deferred income taxes
11.3

 
8.0

   Prepaid expenses and other
72.1

 
72.6

Total current assets
763.1

 
602.1

 
 
 
 
Property, plant and equipment, net
971.2

 
936.3

Deferred income taxes
20.1

 
38.6

Goodwill
155.9

 
155.8

GM postretirement cost sharing asset
260.2

 
244.4

Other assets and deferred charges
158.2

 
137.5

Total assets
$
2,328.7

 
$
2,114.7

 
 
 
 
Liabilities and Stockholders' Deficit
 
 
 
Current liabilities
 
 
 
   Accounts payable
$
337.1

 
$
283.6

   Accrued compensation and benefits
110.6

 
115.1

   Deferred revenue
32.9

 
79.9

   Deferred income taxes
9.9

 
8.9

   Other accrued expenses
85.6

 
81.6

Total current liabilities
576.1

 
569.1

 
 
 
 
Long-term debt
1,180.2

 
1,010.0

Deferred income taxes
7.7

 
6.6

Deferred revenue
88.2

 
116.0

Postretirement benefits and other long-term liabilities
896.1

 
881.1

Total liabilities
2,748.3

 
2,582.8

 
 
 
 
Stockholders' deficit
 
 
 
Series A junior participating preferred stock, par value $0.01 per share;
 
 
 
0.1 million shares authorized; no shares outstanding in 2011 or 2010

 

Preferred stock, par value $0.01 per share; 10.0 million shares
 
 
 
authorized; no shares outstanding in 2011 or 2010

 

Common stock, par value $0.01 per share; 150.0 million shares authorized;
 
 
 
79.3 million and 74.3 million shares issued and outstanding in 2011 and 2010, respectively
0.8

 
0.8

Series common stock, par value $0.01 per share; 40.0 million
 
 
 
shares authorized; no shares outstanding in 2011 or 2010

 

Paid-in capital
597.2

 
588.1

Accumulated deficit
(643.5
)
 
(786.3
)
  Treasury stock at cost, 5.5 million shares in 2011 and 2010
(176.2
)
 
(176.1
)
Accumulated other comprehensive income (loss), net of tax
 
 
 
     Defined benefit plans
(215.6
)
 
(152.1
)
     Foreign currency translation adjustments
17.3

 
44.8

     Unrecognized gain (loss) on derivatives
(5.5
)
 
1.3

Total AAM stockholders' deficit
(425.5
)
 
(479.5
)
     Noncontrolling interests in subsidiaries
5.9

 
11.4

Total stockholders' deficit
(419.6
)
 
(468.1
)
Total liabilities and stockholders' deficit
$
2,328.7

 
$
2,114.7


See accompanying notes to consolidated financial statements

39

AMERICAN AXLE & MANUFACTURING HOLDINGS, INC.

Consolidated Statements of Cash Flows
Year Ended December 31,
 
2011
 
2010
 
2009
 
 
 
(in millions)
 
 
Operating Activities
 
 
 
 
 
Net income (loss)
$
137.1

 
$
114.5

 
$
(253.3
)
Adjustments to reconcile net income (loss) to net cash provided by (used in) operating activities
 
 
 
 
 
Asset impairments and related indirect inventory obsolescence
8.7

 
8.7

 
151.7

Depreciation and amortization
139.4

 
131.6

 
134.7

Deferred income taxes
17.2

 
(8.0
)
 
(18.9
)
Stock-based compensation
4.5

 
9.4

 
13.6

Pensions and other postretirement benefits, net of contributions
(33.3
)
 
(28.8
)
 
(83.4
)
(Gain) loss on retirement of equipment and held-for-sale assets, net
(6.9
)
 
2.9

 
0.7

Debt refinancing and redemption costs
1.8

 

 
7.7

Changes in operating assets and liabilities
 
 
 
 
 
Accounts receivable
(189.9
)
 
(14.8
)
 
118.9

Inventories
(50.2
)
 
(38.9
)
 
19.6

Accounts payable and accrued expenses
37.1

 
112.0

 
(50.7
)
Deferred revenue
(74.7
)
 
(70.1
)
 
20.9

Other assets and liabilities
(47.1
)
 
21.8

 
(45.6
)
Net cash provided by (used in) operating activities
(56.3
)
 
240.3

 
15.9

 
 
 
 
 
 
Investing activities
 
 
 
 
 
Purchases of property, plant and equipment
(163.1
)
 
(108.3
)
 
(137.7
)
Proceeds from sale of property, plant and equipment
8.9

 
4.9

 
1.7

Purchase buyouts of leased equipment
(13.4
)
 
(7.8
)
 

Acquisition, net
(16.5
)
 
(2.2
)
 
(10.2
)
Redemption of short-term investments

 
6.4

 
71.6

Net cash used in investing activities
(184.1
)
 
(107.0
)
 
(74.6
)
 
 
 
 
 
 
Financing activities
 
 
 
 
 
Net short-term borrowings (repayments) under credit facilities
2.6

 
(60.0
)
 
(163.1
)
Proceeds from issuance of long-term debt
227.0

 
6.2

 
854.8

Payment of Term Loan

 

 
(250.0
)
Payments of other long-term debt and capital lease obligations
(56.0
)
 
(8.1
)
 
(516.8
)
Debt issuance costs
(10.9
)
 
(2.2
)
 
(32.9
)
Purchase of noncontrolling interest

 
(2.1
)
 

Proceeds from issuance of common stock, net

 

 
109.7

Proceeds from issuance of warrants to GM

 

 
30.3

Employee stock option exercises, including tax benefit
4.6

 
1.1

 
1.0

Purchase of treasury stock
(0.1
)
 
(1.3
)
 
(0.9
)
Net cash provided by (used in) financing activities
167.2

 
(66.4
)
 
32.1

 
 
 
 
 
 
Effect of exchange rate changes on cash
(2.2
)
 
(0.4
)
 
5.9

 
 
 
 
 
 
Net increase (decrease) in cash and cash equivalents
(75.4
)
 
66.5

 
(20.7
)
 
 
 
 
 
 
Cash and cash equivalents at beginning of year
244.6

 
178.1

 
198.8

 
 
 
 
 
 
Cash and cash equivalents at end of year
$
169.2

 
$
244.6

 
$
178.1

 
 
 
 
 
 
Supplemental cash flow information
 
 
 
 
 
Interest paid
$
73.1

 
$
61.6

 
$
80.0

Income taxes paid (refunds received)
$
10.9

 
$
(43.1
)
 
$
3.8


See accompanying notes to consolidated financial statements

40

AMERICAN AXLE & MANUFACTURING HOLDINGS, INC.

Consolidated Statement of Stockholders' Deficit
 
 
 
 
 
 
Accumulated Other
 
 
 
 
Common Stock
 
 
 
Comprehensive
Comprehensive
Noncontrolling
 
 
Shares
Par
Paid-in
Accumulated
Treasury
Income (Loss)
Income (Loss)
Interest in
Comprehensive
 
Outstanding
Value
Capital
Deficit
Stock
Attributable to AAM
Attributable to AAM
Subsidiaries
Income (Loss)
 
(in millions)
 
 
 
 
 
 
 
 
 
 
Balance at January 1, 2009
51.7

$
0.6

$
426.7

$
(648.6
)
$
(173.9
)
$
(40.5
)
 
$
0.2

 
 
 
 
 
 
 
 
 
 
 
Net loss
 
 
 
(253.1
)
 
 
$
(253.1
)
$
(0.2
)
$
(253.3
)
Change in derivatives, net
 
 
 
 
 
11.4

11.4

 
11.4

Foreign currency translation, net
 
 
 
 
 
37.2

37.2

0.4

37.6

Defined benefit plans, net
 
 
 
 
 
(72.5
)
(72.5
)
 
(72.5
)
Total comprehensive income (loss)
 
 
 
 
 
 
$
(277.0
)
$
0.2

$
(276.8
)
Proceeds from issuance of common stock, net
16.1

0.2

109.5

 
 
 
 
 
 
Proceeds from issuance of warrants to GM
 
 
30.3

 
 
 
 
 
 
Change in noncontrolling interest ownership
 
 
 
 
 
 
 
(0.1
)
 
Exercise of stock options and vesting of restricted stock
0.6

 
1.0

 
 
 
 
 
 
Stock-based compensation
 
 
12.4

 
 
 
 
 
 
Purchase of treasury stock

 
 
 
(0.9
)
 
 
 
 
Balance at December 31, 2009
68.4

$
0.8

$
579.9

$
(901.7
)
$
(174.8
)
$
(64.4
)
 
$
0.3

 
 
 
 
 
 
 
 
 
 
 
Net income (loss)
 
 
 
115.4

 
 
$
115.4

$
(0.9
)
$
114.5

Change in derivatives, net
 
 
 
 
 
1.3

1.3

 
1.3

Foreign currency translation, net
 
 
 
 
 
7.4

7.4

(0.1
)
7.3

Defined benefit plans, net
 
 
 
 
 
(50.3
)
(50.3
)
 
(50.3
)
Total comprehensive income (loss)
 
 
 
 
 
 
$
73.8

$
(1.0
)
$
72.8

Issuance of noncontrolling interest in e-AAM
 
 
 
 
 
 
 
12.0

 
Acquisition of noncontrolling interest
 
 
(2.1
)
 
 
 
 
0.1

 
Exercise of stock options and vesting of restricted stock
0.5

 
1.1

 
 
 
 
 
 
Stock-based compensation
 
 
9.2

 
 
 
 
 
 
Purchase of treasury stock
(0.1
)
 
 
 
(1.3
)
 
 
 
 
Balance at December 31, 2010
68.8

$
0.8

$
588.1

$
(786.3
)
$
(176.1
)
$
(106.0
)
 
$
11.4

 
 
 
 
 
 
 
 
 
 
 
Net income (loss)
 
 
 
142.8

 
 
$
142.8

$
(5.7
)
$
137.1

Change in derivatives, net
 
 
 
 
 
(6.8
)
(6.8
)
 
(6.8
)
Foreign currency translation, net
 
 
 
 
 
(27.5
)
(27.5
)
0.2

(27.3
)
Defined benefit plans, net
 
 
 
 
 
(63.5
)
(63.5
)
 
(63.5
)
Total comprehensive income (loss)
 
 
 
 
 
 
$
45.0

$
(5.5
)
$
39.5

Exercise of stock options and vesting of restricted stock
1.7

 
4.6

 
 
 
 
 
 
Stock-based compensation
 
 
4.5