The experience over the past two years has resulted in
a range of plus or minus 0.5% for the combined gross margin
of all contracts in the Military Aircraft and Missile Systems
and the Space and Communications segments. If combined gross
margin for all contracts in the Military Aircraft and Missile
Systems and the Space and Communications segments for all
of 2002 had been estimated to be higher or lower by 0.5% it
would have increased or decreased income for the year by approximately
$125 million.
Program accounting
The Company uses program accounting for its 7-series commercial
airplane programs. Program accounting is a method of accounting
for the costs of certain products manufactured for delivery
under production type contracts where profitability is realized
over multiple contracts and years. Under program accounting,
inventoriable production costs (including overhead), program
tooling costs and warranty costs are accumulated and charged
to revenue by program instead of by individual units or contracts.
A program consists of the estimated number of units (accounting
quantity) of a product to be produced in a continuing, long-term
production effort for delivery under existing and anticipated
contracts. To establish the relationship of revenue to cost
of sales, program accounting requires estimates of (a) the
number of units to be produced and sold in a program, (b)
the period over which the units can reasonably be expected
to be produced, and (c) their expected selling prices, production
costs, program tooling, and warranty costs for the total program.
The reliance on estimates in the use of program accounting
requires the demonstrated ability to reliably estimate the
cost-revenue relationship for the defined program accounting
quantity. The factors that must be estimated include selling
price, labor and employee benefit costs, material costs, procured
parts and major component costs, and overhead costs. To meet
this requirement the Company employs a rigorous estimating
process that is reviewed and updated on a quarterly basis.
Changes in estimate are recognized on a prospective basis.
Underlying all estimates used for program accounting is the
assumed market and the corresponding production rates. The
program accounting quantity is established based upon the
assumed market. The total program revenue is determined by
estimating the model mix and sales price for all unsold units
within the accounting quantity added together with the revenue
for all undelivered units under contract. The sales prices
for all undelivered units within the accounting quantity include
an escalation adjustment that is based on projected escalation
rates. Cost estimates are based in a large part on historical
performance trends, business base and other economic projections,
and information provided by suppliers. Factors that influence
these estimates include production rates, internal and subcontractor
performance trends, asset utilization, anticipated labor agreements,
and inflationary trends.
The Company recognizes revenue for commercial airplanes when
a unit is completed and accepted by the customer. The revenue
recognized is the price negotiated with the customer including
special features adjusted by an escalation formula. The amount
reported as cost of sales is determined by applying the estimated
cost of sales percentage for the total remaining program to
the amount of revenue recognized for the quarter. Because
of the higher unit production costs experienced at the beginning
of a new airplane program (known as the learning curve effect),
the actual costs incurred for production of the early units
in the program will exceed the amount reported as cost of
sales for those units. This difference known as deferred production
costs is included in inventory along with unamortized tooling
costs. |
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The experience of the last two years, with all programs
being relatively mature, has been that estimate changes due
to model mix, escalation, cost performance, and accounting
quantity increases have resulted in a range of plus or minus
0.5% for the combined gross margin of all commercial airplane
programs. If combined gross margin for all commercial airplane
programs for all of 2002 had been estimated to be higher or
lower by 0.5% it would have increased or decreased income
for the year by approximately $122 million.
Aircraft valuation
Used aircraft under trade-in
agreements The Company enters into certain trade-in
agreements to purchase used aircraft from customers at a specific
price at a future point in time when those customers purchase
new aircraft from the Company. In the event the Company accepts
an aircraft under a trade-in agreement, the aircraft purchased
by the Company serves as collateral to offset amounts paid
by the Company to the customer.
Obligations recorded from trade-in aircraft agreements are
measured as the difference between gross amounts payable to
customers and the estimated fair value of the collateral.
The fair value of collateral is determined using a process
based on the net present value of expected future cash flows
from the trade-in aircraft, assuming the most likely market
placement of the aircraft. The first step in this process
uses the Company’s assessment of the market for each trade-in
aircraft, which in most instances begins years before the
return of the aircraft. There are several possible markets
to which the Company continually pursues opportunities to
place used aircraft. These markets include, but are not limited
to, (1) the resale market, which could potentially include
the cost of long-term storage, (2) the leasing market, with
the potential for refurbishment costs to meet the leasing
customer’s requirements, or (3) the scrap market. Collateral
valuation varies significantly depending on which market the
Company determines is most likely for each aircraft. On a
quarterly basis, the Company updates its valuation analysis
based on the actual activities associated with placing each
aircraft into a market. This quarterly collateral valuation
process yields results that are typically lower than residual
value estimates by independent sources and tends to more accurately
reflect results upon the actual placement of the aircraft.
Based on the best market information available at the time,
the Company deemed it probable that it would be obligated
to perform on trade-in agreements with gross amounts payable
to customers totaling $1,370 million and $1,340 million as
of December 31, 2002 and 2001, respectively. Accounts payable
and other liabilities included $156 million and $189 million
as of December 31, 2002 and 2001, respectively, which represents
the trade-in aircraft exposure related to these trade-in agreements. |
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