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Restructuring Accruals, Asset Impairments and Other Costs Related to Closed Facilities
12 Months Ended
Dec. 31, 2012
Restructuring Accruals, Asset Impairments and Other Costs Related to Closed Facilities  
Restructuring Accruals, Asset Impairments and Other Costs Related to Closed Facilities

8. Restructuring Accruals, Asset Impairments and Other Costs Related to Closed Facilities

        The Company continually reviews its manufacturing footprint and operating cost structure and may decide to close operations or reduce headcount to gain efficiencies, integrate acquired operations and reduce future expenses. The Company incurs costs associated with these actions including employee severance and benefits, other exit costs such as those related to contract terminations, and asset impairment charges. The Company also may incur other costs related to closed facilities including environmental remediation, clean up, dismantling and preparation for sale or other disposition.

        The Company accounts for restructuring and other costs under applicable provisions of generally accepted accounting principles. Charges for employee severance and related benefits are generally accrued based on contractual arrangements with employees or their representatives. Other exit costs are accrued based on the estimated cost to settle related contractual arrangements. Estimated environmental remediation costs are accrued when specific claims have been received or are probable of being received.

        The Company's decisions to curtail selected production capacity have resulted in write downs of certain long-lived assets to the extent their carrying amounts exceeded fair value or fair value less cost to sell. The Company classified the significant assumptions used to determine the fair value of the impaired assets as Level 3 in the fair value hierarchy as set forth in the general accounting principles for fair value measurements.

        When a decision is made to take these actions, the Company manages and accounts for them programmatically apart from the on-going operations of the business. Information related to major programs (as in the case of the European Asset Optimization and Asia Pacific Restructuring programs below) are presented separately. Minor initiatives are presented on a combined basis as Other Restructuring Actions. When charges related to major programs are completed, remaining accrual balances are classified with Other Restructuring Actions.

European Asset Optimization

        In 2011, the Company implemented the European Asset Optimization program to increase the efficiency and capability of its European operations and to better align its European manufacturing footprint with market and customer needs. This program involves making additional investments in certain facilities and addressing assets with higher cost structures. As part of this program, the Company recorded charges of $86 million in 2012 and $24 million in 2011 for employee costs, asset impairments and environmental remediation related to decisions to close furnaces and manufacturing facilities in Europe. The Company expects to execute further actions under this program in phases over the next several years.

Asia Pacific Restructuring

        In 2011, the Company implemented a restructuring plan in its Asia Pacific segment, primarily related to aligning its supply base with lower demand in the region. As part of this plan, the Company recorded charges of $47 million and $46 million in 2012 and 2011, respectively, for employee costs and asset impairments related to furnace closures and additional restructuring activities.

Other Restructuring Actions

        The Company took certain other restructuring actions and recorded charges in 2012 of $13 million for employee costs and asset impairments related to a decision to close a machine manufacturing facility in the U.S., $7 million for employee costs and asset impairments related to a decision to close a mold shop in South America and $15 million for miscellaneous other costs. In 2011, the Company recorded charges of $13 million related to headcount reductions, primarily in Europe and South America, and $12 million for an asset impairment related to a previously closed facility in Europe.

        The Company acquired VDL in 2011 (see Note 20). As part of this acquisition, the Company assumed the severance liability of VDL related to a headcount reduction program initiated prior to the acquisition.

        The beginning accrual balance for other restructuring actions as of January 1, 2011 primarily relates to the Company's strategic review of its global manufacturing footprint completed in 2010.

        The following table presents information related to restructuring, asset impairment and other costs related to closed facilities:

 
  European
Asset
Optimization
  Asia Pacific
Restructuring
  Other
Restructuring
Actions
  Total
Restructuring
 

Balance at January 1, 2011

  $   $   $ 79   $ 79  

2011 charges

    24     46     25     95  

Write-down of assets to net realizable value

    (11 )   (8 )   (21 )   (40 )

Net cash paid, principally severance and related benefits

    (1 )   (21 )   (17 )   (39 )

Acquisition

                11     11  

Other, including foreign exchange translation

                (3 )   (3 )
                   

Balance at December 31, 2011

    12     17     74     103  

2012 charges

    86     47     35     168  

Write-down of assets to net realizable value

    (30 )   (22 )   (16 )   (68 )

Net cash paid, principally severance and related benefits

    (16 )   (25 )   (25 )   (66 )

Pension charges transferred to other accounts

          (11 )   (4 )   (15 )

Other, including foreign exchange translation

    1                 1  
                   

Balance at December 31, 2012

  $ 53   $ 6   $ 64   $ 123  
                   

        The restructuring accrual balance represents the Company's estimates of the remaining future cash amounts to be paid related to the actions noted above. As of December 31, 2012, the Company's estimates include approximately $77 million for severance and related benefits costs, $34 million for environmental remediation costs, and $12 million for other exit costs. The 2012 charges include approximately $14 million related to environmental remediation costs at a closed facility in Europe.