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Restructuring, Reorganization, Relocation and Severance
12 Months Ended
Dec. 31, 2011
Restructuring and Related Activities [Abstract]  
Restructuring, Reorganization, Relocation and Severance
RESTRUCTURING, REORGANIZATION, RELOCATION AND SEVERANCE
Manufacturing Transfer
In 2008 we entered into an arrangement to outsource aspects of our manufacturing processes. In 2011, we notified our largest contract manufacturer, accounting for approximately 10% of our revenue, that we plan to terminate the arrangement and to take over the manufacturing process. The termination contract was signed during the fourth quarter of 2011 and will be executed during the first quarter of 2012. We incurred $2.1 million of costs associated with the termination of the outsourcing arrangement.
April 2010 Restructuring
On April 12, 2010, we announced a restructuring program to consolidate the manufacturing of our small DualBeam product line by relocating manufacturing activities currently performed at our facility in Eindhoven, The Netherlands to our facility in Brno, Czech Republic. The balance of our small DualBeam product line is already based in Brno. The move, which has been substantially completed, resulted in severance costs, costs to transfer the product line, costs to train Brno employees and costs to build-out the existing Brno facility to add capacity for the additional small DualBeam production. In addition to the product line move, the April 2010 restructuring plan involved organizational changes designed to improve the efficiency of our finance, research and development and other corporate programs and improve our market focus. Costs incurred in connection with this plan were related to the consolidation of the manufacturing of our small DualBeam product line in Brno.
Information for costs related to the April 2010 restructuring plan is as follows (in thousands):
 
Year Ended December 31,
 
 
Costs Incurred
2011
 
2010
 
Life of Plan
Severance costs related to work force reduction and reorganization
$
184

 
$
6,433

 
$
6,617

Product line transfer, training of Brno employees and facility build-out in Brno
963

 
872

 
1,835

Total costs incurred
$
1,147

 
$
7,305

 
$
8,452


All of the costs incurred resulted in cash expenditures. We do not expect to incur significant additional costs associated with this plan.
April 2008 Restructuring
Our April 2008 restructuring plan was related to improving the efficiency of our operations and improving the currency balance in our supply chain so that more of our costs are denominated in dollar or dollar-linked currencies. Also included in these costs were amounts related to IT system upgrades, which were expected to increase the efficiency of our manufacturing operations. These activities reduced operating expenses, improved our factory utilization and helped to offset the effect of currency fluctuations on our cost of goods sold. The main activities and related costs are described in the table below.
The April 2008 restructuring plan was completed in 2010. Total costs incurred related to this plan were $11.6 million. In 2010 and 2009, we incurred $3.8 million and $3.5 million, respectively, under the April 2008 restructuring plan and incurred no additional costs related to this plan in 2011. All of the costs resulted in cash expenditures and we do not expect to incur any additional costs under this plan.
A summary of the expenses related to our April 2008 restructuring plan is as follows:
Costs Incurred
Life of Plan
Severance costs related to work force reduction
$ 3.3 million
Transfer of manufacturing and other activities
        0.3 million
Shift of supply chain
        5.9 million
IT system upgrades
        2.1 million

Restructuring, Reorganization, Relocation and Severance Accrual
The following tables summarize the charges, expenditures and write-offs and adjustments related to our restructuring, reorganization, relocation and severance accrual (in thousands):
Year Ended December 31, 2011
Product line transfer and training of Brno employees
 
Severance, outplacement and related benefits for terminated employees
 
IT system upgrades
 
Abandoned leases, leasehold improvements and facilities
 
Manufacturing transfer
 
Total
Beginning accrued liability
$

 
$
4,832

 
$
20

 
$
32

 
$

 
$
4,884

Charged to expense, net
963

 
184

 

 
(32
)
 
2,100

 
3,215

Expenditures
(963
)
 
(5,083
)
 

 

 

 
(6,046
)
Write-offs and adjustments

 
180

 
(20
)
 

 

 
160

Ending accrued liability
$

 
$
113

 
$

 
$

 
$
2,100

 
$
2,213

Year Ended December 31, 2010
Product line transfer and training of Brno employees
 
Severance, outplacement and related benefits for terminated employees
 
Transfer of manufacturing and related activities and shift of supply chain
 
IT system upgrades
 
Abandoned leases, leasehold improvements and facilities
 
Total
Beginning accrued liability
$

 
$

 
$

 
$

 
$
32

 
$
32

Charged to expense, net
872

 
6,777

 
1,312

 
2,106

 

 
11,067

Expenditures
(872
)
 
(2,342
)
 
(1,312
)
 
(2,086
)
 

 
(6,612
)
Write-offs and adjustments

 
397

 

 

 

 
397

Ending accrued liability
$

 
$
4,832

 
$

 
$
20

 
$
32

 
$
4,884

Year Ended December 31, 2009
Product line transfer and training of Brno employees
 
Severance, outplacement and related benefits for terminated employees
 
Transfer of manufacturing and related activities and shift of supply chain
 
IT system upgrades
 
Abandoned leases, leasehold improvements and facilities
 
Total
Beginning accrued liability
$

 
$
221

 
$

 
$

 
$
19

 
$
240

Charged to expense, net

 
94

 
3,336

 

 
26

 
3,456

Expenditures

 
(288
)
 
(3,339
)
 

 
(10
)
 
(3,637
)
Write-offs and adjustments

 
(27
)
 
3

 

 
(3
)
 
(27
)
Ending accrued liability
$

 
$

 
$

 
$

 
$
32

 
$
32