UNITED STATES SECURITIES AND EXCHANGE COMMISSION WASHINGTON, D.C. 20549 FORM 10-K (MARK ONE) [X] ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 [NO FEE REQUIRED] FOR THE FISCAL YEAR ENDED DECEMBER 31, 2004 OR [ ] TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 [NO FEE REQUIRED] COMMISSION FILE NUMBER 1-8514 SMITH INTERNATIONAL, INC. (EXACT NAME OF REGISTRANT AS SPECIFIED IN ITS CHARTER) DELAWARE 95-3822631 (STATE OR OTHER JURISDICTION OF (I.R.S. EMPLOYER INCORPORATION OR ORGANIZATION) IDENTIFICATION NO.) 411 NORTH SAM HOUSTON PARKWAY, SUITE 600 77060 HOUSTON, TEXAS (ZIP CODE) (ADDRESS OF PRINCIPAL EXECUTIVE OFFICES) REGISTRANT'S TELEPHONE NUMBER, INCLUDING AREA CODE: (281) 443-3370 SECURITIES REGISTERED PURSUANT TO SECTION 12(b) OF THE ACT: COMMON STOCK, $1.00 PAR VALUE NEW YORK STOCK EXCHANGE, INC. (TITLE OF EACH CLASS) PACIFIC EXCHANGE, INC. (NAME OF EACH EXCHANGE ON WHICH REGISTERED) SECURITIES REGISTERED PURSUANT TO SECTION 12(g) OF THE ACT: NONE 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 ----- ----- 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 the 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 an accelerated filer (as defined in Rule 12b-2 of the Securities Exchange Act of 1934). Yes [X] No [ ]. The aggregate market value of the voting stock held by non-affiliates on June 30, 2004 was $5,751,836,149 (103,153,446 shares at the closing price on the New York Stock Exchange of $55.76). On June 30, 2004, 104,780,238 shares of common stock were outstanding. For this purpose all shares held by officers and directors and their respective affiliates are considered to be held by affiliates, but neither the Registrant nor such persons concede that they are affiliates of the Registrant. There were 106,122,507 shares of common stock outstanding on March 8, 2005. DOCUMENTS INCORPORATED BY REFERENCE Portions of the Proxy Statement related to the Registrant's 2005 Annual Meeting of Stockholders are incorporated by reference into Part III of this Form. TABLE OF CONTENTS PART I Item 1. Business.......................................................... 2 Item 2. Properties........................................................ 10 Item 3. Legal Proceedings................................................. 10 Item 4. Submission of Matters to a Vote of Security Holders............... 11 PART II Item 5. Market for the Registrant's Common Equity, Related Stockholder Matters and Issuer Purchases of Equity Securities.............. 11 Item 6. Selected Financial Data........................................... 12 Item 7. Management's Discussion and Analysis of Financial Condition and Results of Operations...................................... 13 Item 7A. Qualitative and Quantitative Market Risk Disclosures.............. 25 Item 8. Financial Statements and Supplementary Data....................... 26 Item 9. Changes in and Disagreements with Accountants on Accounting and Financial Disclosure............................ 55 Item 9A. Controls and Procedures........................................... 55 Item 9B. Other Information................................................. 55 PART III Item 10. Directors and Executive Officers of the Registrant................ 55 Item 11. Executive Compensation............................................ 55 Item 12. Security Ownership of Certain Beneficial Owners and Management.... 55 Item 13. Certain Relationships and Related Transactions.................... 55 Item 14. Principal Accountant Fees and Services............................ 55 PART IV Item 15. Exhibits, Financial Statement Schedule and Reports on Form 8-K.... 56 PART I ITEM 1. BUSINESS GENERAL Smith International, Inc. ("Smith" or the "Company") is a leading worldwide supplier of premium products and services to the oil and gas exploration and production industry, the petrochemical industry and other industrial markets. The Company provides a comprehensive line of technologically-advanced products and engineering services, including drilling and completion fluid systems, solids-control equipment, waste-management services, production chemicals, three-cone and diamond drill bits, turbines, fishing services, drilling tools, underreamers, casing exit and multilateral systems, packers and liner hangers. The Company also offers supply-chain management solutions through an extensive North American branch network providing pipe, valves, fittings, mill, safety and other maintenance products. The Company was incorporated in the state of California in January 1937 and reincorporated under Delaware law in May 1983. The Company's executive offices are headquartered at 411 North Sam Houston Parkway, Suite 600, Houston, Texas 77060 and its telephone number is (281) 443-3370. The Company's 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 Exchange Act of 1934 are made available free of charge on the Company's Internet website at www.smith.com as soon as reasonably practicable after the Company has electronically filed such material with, or furnished it to, the Securities and Exchange Commission. The Company's Corporate Governance Guidelines, Code of Business Conduct and Ethics and the charters of the Audit Committee, Compensation and Benefits Committee and Nominating and Corporate Governance Committee are also available on the Investor Relations section of the Company's Internet website. Printed copies of these documents are available to stockholders upon request. The Company's operations are aggregated into two reportable segments: Oilfield Products and Services and Distribution. The Oilfield Products and Services segment consists of: M-I SWACO, which provides drilling and completion fluid systems and services, solids-control and separation equipment, waste-management services and oilfield production chemicals; Smith Technologies, which manufactures and sells three-cone drill bits, diamond drill bits and turbine products; and Smith Services, which manufactures and markets products and services used for drilling, workover, well completion and well re-entry operations. The Distribution segment consists of one business unit, Wilson, which markets pipe, valves and fittings as well as mill, safety and other maintenance products to energy and industrial markets. Financial information regarding reportable segments and international operations appears in "Management's Discussion and Analysis of Financial Condition and Results of Operations" and in Note 16 of the Notes to Consolidated Financial Statements included elsewhere in this Form 10-K. Information related to business combinations appears in Note 4 of the Notes to Consolidated Financial Statements included elsewhere in this Form 10-K. BUSINESS OPERATIONS Oilfield Products and Services Segment M-I SWACO Fluid Products and Services. The Company is a leading worldwide provider of drilling, reservoir drill-in and completion fluid systems, products and engineering services to end users engaged in drilling oil and natural gas wells. Drilling fluids are used to cool and lubricate the bit during drilling operations, contain formation pressures, suspend and remove rock cuttings from the hole and maintain the stability of the wellbore. Engineering services are provided to ensure that the fluid products are applied effectively to optimize drilling operations. These services include recommending products and services during the well planning phase; monitoring drilling fluid properties; recommending adjustments during the drilling phase; and analyzing/benchmarking well results after completion of the project to improve the efficiencies of future wells. M-I SWACO offers water-base, oil-base and synthetic-base drilling fluid systems. Water-base drilling fluids are the world's most widely utilized systems, having application in both land and offshore environments. Typically, these systems comprise an engineered blend of weighting materials used to contain formation pressures, and a broad range of chemical additives, designed to yield the specific drilling performance characteristics required for a given drilling project. Oil-base drilling fluids, which primarily are used to drill water-sensitive shales, reduce torque and drag and are widely used in areas where stuck 2 pipe is likely to occur. In certain drilling areas of the world, oil-base systems exhibit comparably higher penetration rates when compared to water-base systems, significantly reducing time on location and overall drilling costs. Synthetic-base drilling fluids are used in drilling environments where oil-base fluids are environmentally prohibited and provide the performance benefits of oil-base systems. Synthetic-base systems are particularly advantageous in the deepwater environment. M-I SWACO also provides a comprehensive line of reservoir drill-in fluids which combine the high performance properties of a premium drilling fluid with minimal damaging characteristics of a brine completion fluid. Completion fluids (clear brines) are solids-free, clear-salt solutions with high specific gravities and are non-damaging to the producing formation. Operators use these specially designed fluid systems in combination with a comprehensive range of specialty chemicals to control bottom-hole pressures, while meeting the specific corrosion inhibition, viscosity and fluid loss requirements necessary during the completion and workover phase of a well. These systems are specially engineered to maximize well production by minimizing formation damage that can be caused by solids-laden systems. M-I SWACO provides a complete line of completion fluids products and services, including low- and high-density brines, specialty chemicals, filtration and chemical treatment services, wellsite engineering and technical and laboratory support services. Fluid Competition. The major competitors in the worldwide drilling fluids market, which approximated $4.0 billion in 2004, are Halliburton Energy Services (a division of Halliburton Company ("Halliburton")) and Baker Hughes Drilling Fluids (a division of Baker Hughes, Inc. ("Baker Hughes")). While M-I SWACO and these companies supply a majority of the market, the drilling fluids industry is highly competitive, with a significant number of smaller, locally based competitors. The major competitors in the worldwide completion fluids market, which approximated $0.7 billion in 2004, are Baroid Completion Fluids (a division of Halliburton), Tetra Technologies, Inc., BJ Services Company and Ambar, Inc. Generally competition for sales of drilling and completions fluids is based on a number of factors, including wellsite engineering services, product quality and availability, technical support, service response and price. M-I SWACO Drilling Waste Management. M-I SWACO provides services, equipment and engineering for solids control, pressure control and waste management to the worldwide drilling market. Solids-control equipment is used to remove drill cuttings from the fluid system, allowing the drilling fluid to be cleaned and recirculated. Solids are normally separated from the drilling fluid using one or a combination of the following: balanced elliptical and linear-motion shale shakers, desanders, disilters, hydroclones, mud cleaners and centrifuges. M-I SWACO designs, manufactures, sells and rents a comprehensive, proprietary line of this equipment for oil and gas drilling processes throughout the world. The Company is also a leading manufacturer and supplier of screens used in solids-control equipment for both oilfield and certain industrial markets. M-I SWACO complements its product offering by providing engineering and technical support to operators and drilling contractors from the planning stages of their projects through waste removal and site remediation. Operators employ M-I SWACO-manufactured pressure-control equipment to drill in sour-gas and high-pressure zones. Well killing and high-pressure control drilling chokes, together with related operating consoles, are used in the drilling process during well kicks and well clean-up and testing operations. Degassers and mud gas separators are designed to remove and vent entrained gases, including toxic gases such as hydrogen sulfide and corrosive oxygen, from the drilling mud. This equipment reduces the risk of dangerous and costly blowouts caused by recirculating mud that contains natural gas. Key products in M-I SWACO's pressure control product line include the MUD D-GASSER(R) and SUPER CHOKE(TM), both of which hold strong market positions as do the SUPER MUD GAS SEPARATOR(TM) and the SUPER AUTOCHOKE(TM). With drilling operations expanding into more environmentally sensitive areas, there has been increased focus on the effective collection, treatment and disposal of waste produced during the drilling of a well. M-I SWACO provides operators with solutions designed to minimize and treat drilling waste. The Company provides a suite of waste handling, minimization and management products and services, including the CLEANCUT(R) pneumatic conveyance system for collection and transportation of drill cuttings related to offshore drilling programs. M-I SWACO also provides rig vacuum systems for cuttings recovery, high-gravity force drying equipment for liquid/solid separation and cuttings slurification and re-injection processes for reducing haul-off waste. In addition, through the THERMAL PHASE SEPARATION(TM) process, M-I SWACO provides operators a proven technology for maximizing the recovery of drilling fluids, while minimizing wastes. M-I SWACO's waste treatment services encompass a wide range of activities, including site assessment, drill cuttings injection, water treatment, pit closure and 3 remediation, bioremediation, dewatering and thermal processing. The Company has established ENVIROCENTERS(R) in Norway, Germany and the United States designed specifically for recovering, treating and recycling solid and liquid drilling wastes. M-I SWACO Drilling Waste Management Competition. M-I SWACO competes with Brandt/Rigtech (a subsidiary of Varco International, Inc.) and Derrick/Oil Tools. Additionally, there are a number of regional suppliers that provide a limited range of equipment and services tailored for local markets. Competition is based on product availability, equipment performance, technical support and price. Oilfield Production Chemicals. M-I SWACO provides a line of oilfield specialty chemicals and related technical services through its Oilfield Production Chemical division, acquired in January 2003. Oilfield production chemicals are used to enhance the flow of hydrocarbons from the wellbore by eliminating paraffin, scale and other byproducts encountered during the production process. Oilfield production chemicals are also used to protect piping and other equipment associated with the production, transportation and processing of oil and gas. Production Chemical Competition. The major competitors in the worldwide oilfield production chemical market include Baker Petrolite (a division of Baker Hughes), Ondeo-Nalco Energy Services (a division of Nalco Company) and Champion Technologies, Inc. Generally, competition is based on product quality, product performance, technical support and price. Smith Technologies Products and Services. Smith Technologies is a worldwide leader in the design, manufacture and marketing of drill bits primarily used in drilling oil and natural gas wells. In addition, Smith Technologies is a leading provider of downhole turbine drilling products (referred to as "turbodrills") and services that enhance the operating performance of petroleum drill bits in certain applications. Smith Technologies' product offerings are designed principally for the premium market segments where faster drilling rates and greater footage drilled provide significant economic benefits in reducing the total cost of a well. Smith Technologies designs, manufactures and markets three-cone drill bits for the petroleum industry, ranging in size from 3 1/2 to 32 inches in diameter. Three-cone bits work by crushing and shearing the rock formation as the bit is turned. These three-cone bits comprise two major components - the body and the cones, which contain different types of pointed structures referred to as "cutting structures" or "teeth." The cutting structures are either an integral part of the steel cone with a hardmetal-applied surface (referred to as "milled tooth") or made of an inserted material (referred to as "insert"), which is usually tungsten carbide. The Company also produces three-cone drill bits in which the tungsten carbide insert is coated with polycrystalline diamond. In certain formations, bits produced with diamond-enhanced inserts last longer and increase penetration rates, which substantially decreases overall drilling costs. Smith Technologies is a leading provider of drill bits utilizing diamond-enhanced insert technology. In addition, Smith Technologies designs, manufactures and markets diamond drill bits. Diamond bits consist of a single body made of either a matrix powder alloy or steel. The cutting structures of diamond bits consist of either polycrystalline diamond cutters, which are brazed on the bit, or natural or synthetic diamonds, which are impregnated in the bit. These bits, which range in size from 2 3/4 to 26 inches in diameter, work by shearing the rock formation with a milling action as the bit is turned. Smith Technologies has experienced increased demand for rental of diamond bits as improved designs and manufacturing processes have allowed a diamond bit to be used to drill multiple wells in certain markets. Smith Technologies also designs, assembles and markets a comprehensive line of turbodrills and provides related technical support. Turbodrills, which operate directly above the drill bit, use the hydraulic energy provided by drilling fluid pumps on the rig floor to deliver torque to and rotate the drill bit. These proprietary tools are designed to provide faster rates of penetration, operate in much higher temperature formations, deliver longer downhole life and produce better wellbore quality than conventional positive displacement drilling motors. The turbine drilling motor provides operators with cost effective solutions in demanding environments such as horizontal applications, hard formations and high-temperature zones. The Company manufactures polycrystalline diamond and cubic boron nitride materials that are used in the Company's three-cone and diamond drill bits and other specialized cutting tools. The Company believes that it is one of the world's largest manufacturers of polycrystalline diamond. Smith Technologies also develops and uses patented processes for applying diamonds to a curved surface which optimize the performance of inserts used in drill bits. As a result, the Company believes that Smith Technologies enjoys 4 a competitive advantage in both material cost and technical ability over other drill bit companies. In addition, the Company's in-house diamond research, engineering and manufacturing capabilities enhance the Company's ability to develop the application of diamond technology across other Smith product lines and into non-energy markets. Competition. Hughes Christensen (a division of Baker Hughes), Security DBS (a division of Halliburton) and ReedHycalog (a division of Grant Prideco, Inc.) are the three major competitors of Smith Technologies in the drill bit business. While Smith Technologies and these companies supply the majority of the worldwide drill bit market, which approximated $1.7 billion in 2004, they compete with more than 20 companies. Generally, competition for sales of drill bits is based on a number of factors, including performance, quality, reliability, service, price, technological advances and breadth of products. The Company believes its quality, reliability and technological advances, such as diamond-enhanced inserts, provide its products with a competitive advantage. Smith Services Products and Services. Smith Services is a leading global provider of technologically advanced drilling, fishing, remedial, multilateral and completion products, services and solutions to the oil and gas drilling industry. Smith Services' Drilling Products and Services business provides a broad range of downhole impact tools for drilling applications as well as numerous other specialized downhole drilling products and services. Smith Services sells and rents impact drilling tools such as the HYDRA-JAR(R) Tool and the ACCELERATOR(R) Tool, which are used to free stuck drill strings during the drilling process. Additionally, drilling performance tools such as the HYDRA-THRUST(R) Tool, used in the drilling process to maintain constant weight on the drill bit, and Drilling on Gauge Subs and Borrox AP Reamers used for maintaining hole gauge and quality of the wellbore, are examples of Smith Services continuous commitment to developing new technology. Smith Services also offers tubular drill string components, such as drill collars, subs, stabilizers, kellys and HEVI-WATE(TM) DrillPipe, and provides related inspection services, including drillstring repair and rebuild services. These components and their placement in the drillstring are supported by engineering and field technical services in order to optimize bottom hole management techniques. Through state-of-the-art software, Smith Services aids the customer in maximizing the life of drillstring components. Rotating control devices for flow control in underbalanced / managed pressure drilling applications and automatic connection torque monitoring and control systems are designed and manufactured by Smith Services. Smith Services also manufactures and markets hole openers and underreamers which are designed to create larger hole diameters in certain sections of the wellbore. The Company's patented RHINO(R) Reamer, REAMASTER(R) and simultaneous drilling and hole enlargement system are three examples of products that aid the customer in realizing lower drilling costs through technology. Through the use of the simultaneous drilling and hole enlargement system above the drill bit, the operator may drill the main bore with the bit and enlarge the diameter of the hole above the drill bit in the same run. Smith Services' Fishing and Remedial Services business provides a comprehensive package of fishing, remedial and thru-tubing services. Fishing operations clear and remove obstructions from a wellbore that may arise during drilling, completion or workover activities or during a well's production phase. This operation requires a wide variety of specialty tools, including fishing jars, milling tools and casing cutters, all of which are manufactured by Smith Services. These tools are operated by Company service personnel or sold or rented to third-party fishing companies. Smith Services provides Wellbore Departure(TM) Systems and Multilateral Junctions through the manufacture of proprietary casing exit tools which are installed by trained technicians. These systems, which include the patented TRACKMASTER(R) Plus Whipstock System and the MX(R) Multilateral Junction, allow the operator to divert around obstructions in the main wellbore or reach multiple production zones from the main wellbore (known as multilateral completions). In addition, Smith Services' GEOTRACK(TM) WHIPSTOCK SYSTEM mills the casing exit and continues to drill several hundred feet of formation in a single trip, saving the customer time and reducing their overall drilling costs. The Company also provides mechanical, hydraulic and explosive pipe-cutting services to remove casing during well or platform abandonment. Smith Services' Completion Systems business specializes in providing fit-for-purpose liner hanger, liner cementing equipment, isolation packers, retrievable and permanent packers, packer products and multilateral completion equipment. Liner hangers allow strings of casing to be suspended within the wellbore without having to extend the string all the way to the surface and are also used to isolate production zones and formations. Most directional and multilateral wells include one or more hangers due to the difficult casing programs and need for zonal isolation. Using Smith Services' POCKET SLIP(TM) liner hanger system, long heavy liners can be suspended with minimal casing distortion and maximum flow-by area. Packers are mechanically or 5 hydraulically actuated devices which lock into place at specified depths in the well and provide a seal between zones through expanding-element systems. The devices therefore create isolated zones within the wellbore to permit either specific formation production or allow for certain operations, such as cementing or acidizing, to take place without damaging the reservoir. Competition. Smith Services' major competitors in the drilling, remedial, re-entry and fishing services markets are Weatherford International, Inc. ("Weatherford"), Baker Oil Tools (a division of Baker Hughes) and numerous small local companies. The main competitors in the liner hanger and packer markets are Baker Oil Tools, Weatherford and TIW Corporation. The main competitors in the drilling and fishing jar market and the fishing product and service market are Weatherford and National-Oilwell, Inc. ("National-Oilwell"). Competition in the drilling and completions sales, rental and services market is primarily based on performance, quality, reliability, service, price and response time and, in some cases, breadth of products. DISTRIBUTION SEGMENT Wilson Products and Services. Wilson is a supply-chain management company which provides products and services to the energy, refining, petrochemical, power generation and mining industries. Wilson operates an extensive network of supply branches, service centers and sales offices through which it markets pipe, valves and fittings as well as mill, safety and other maintenance products, predominately in the United States and Canada. In addition, Wilson provides warehouse management, vendor integration and various surplus and inventory management services. The majority of Wilson's operations are focused on North American distribution of maintenance, repair and operating supplies and equipment with the remainder associated with line pipe and automated valve products (including valve, actuator and control packages). Approximately two-thirds of Wilson's 2004 revenues were generated in the energy sector, which includes exploration and production companies and companies with operations in the petroleum industry's pipeline sector. The remainder related to sales in the downstream and industrial market, including refineries, petrochemical and power generation plants and other energy-focused operations. Competition. Wilson's competitors in its energy segment operations include National-Oilwell, Redman Pipe and Supply Company and a significant number of smaller, locally based operations. Wilson's competitors in the downstream and industrial market include Hagemeyer NV, Ferguson Enterprises, Inc., McJunkin Corporation and W.W. Grainger, Inc. The distribution market that Wilson participates in is highly competitive. Generally, competition involves numerous factors, including price, experience, customer service and equipment availability. NON-U.S. OPERATIONS Sales to oil and gas exploration and production markets outside the United States are a key strategic focus of Smith's management. The Company markets its products and services through subsidiaries, joint ventures and sales agents located in virtually all petroleum-producing areas of the world, including Canada, Europe/Africa, the Middle East, Latin America and the Far East. Approximately 55 percent, 56 percent and 53 percent of the Company's revenues in 2004, 2003 and 2002, respectively, were derived from equipment or services sold or provided outside the United States. The Company's Distribution operations constitute a significant portion of the consolidated revenue base and are concentrated in North America which serves to distort the geographic revenue mix of the Company's Oilfield segment operations. Excluding the impact of the Distribution operations, 65 percent, 65 percent and 64 percent of the Company's revenues were generated in non-U.S. markets in 2004, 2003 and 2002, respectively. Historically, drilling activity outside the United States has been less volatile than U.S. based activity as the high cost exploration and production programs outside the United States are generally undertaken by major oil companies, consortiums and national oil companies. These entities operate under longer-term strategic priorities than do the independent drilling operators that are more common in the U.S. market. 6 SALES AND DISTRIBUTION Sales and service efforts are directed to end users in the exploration and production industry, including major and independent oil companies, national oil companies and independent drilling contractors. The Company's products and services are primarily marketed through the direct sales force of each business unit. In certain non-U.S. markets where direct sales efforts are not practicable, the Company utilizes independent sales agents, distributors or joint ventures. Smith maintains field service centers, which function as repair and maintenance facilities for rental tools, operations for remedial and completion service and a base for the Company's global sales force, in all major oil and gas producing regions of the world. The location of these service centers near the Company's customers is an important factor in maintaining favorable customer relations. MANUFACTURING The Company's manufacturing operations, along with quality control support, are designed to ensure that all products and services marketed by the Company will meet standards of performance and reliability consistent with the Company's reputation in the industry. Management believes that it generally has sufficient internal manufacturing capacity to meet anticipated demand for its products and services. During periods of peak demand, certain business units utilize outside resources to provide additional manufacturing capacity. RAW MATERIALS Through its company-owned mines in and outside the United States, M-I SWACO has the capability to produce a large portion of its requirements for barite and bentonite. Barite reserves are mined in the United States, the United Kingdom and Morocco. Bentonite is produced from ore deposits in the United States. Mining exploration activities continue worldwide to locate and evaluate ore bodies to ensure deposits are readily available for production when market conditions dictate. In addition to its own production, M-I SWACO purchases the majority of its worldwide barite requirement from suppliers outside the United States, mainly the People's Republic of China, India and Morocco. The Company purchases a variety of raw materials for its Smith Technologies and Smith Services units, including alloy and stainless steel bars, tungsten carbide inserts and forgings. Generally, the Company is not dependent on any single source of supply for any of its raw materials or purchased components, and believes that numerous alternative supply sources are available for all such materials. The Company does not expect any interruption in supply, but there can be no assurance that there will be no price or supply issues over the long-term. The Company produces polycrystalline diamond materials in Provo, Utah and Scurelle, Italy for utilization in various Company products as well as direct customer sales. The Company believes that it enjoys a competitive advantage in the manufacture of diamond drill bits because it is the only diamond drill bit producer with substantial polycrystalline diamond manufacturing capabilities. PRODUCT DEVELOPMENT, ENGINEERING AND PATENTS The Company's business units maintain product development and engineering departments whose activities are focused on improving existing products and services and developing new technologies to meet customer demands for improved drilling performance and environmental-based solutions for drilling and completion operations. The Company's primary research facilities are located in Houston, Texas; Stavanger, Norway; Aberdeen, Scotland; and Florence, Kentucky. The Company also maintains a drill bit database which records the performance of drill bits over the last 19 years, including those manufactured by competitors. This database gives the Company the ability to monitor, among other things, drill bit failures and performance improvements related to product development. The Company believes this proprietary database gives it a competitive advantage in the drill bit business. The Company has historically invested significant resources in research and engineering in order to provide customers with broader product lines and technologically-advanced products and services. The Company's expenditures for research and engineering activities are attributable to the Company's Oilfield Products and Services segment and totaled $67.2 million in 2004, 7 $55.6 million in 2003 and $50.6 million in 2002. In 2004, research and engineering expenditures approximated 2.1 percent of the Company's Oilfield Products and Services segment revenues. Although the Company has over 2,000 issued and pending patents and regards its patents and patent applications as important in the operation of its business, it does not believe that any significant portion of its business is materially dependent upon any single patent. EMPLOYEES At December 31, 2004, the Company had 13,235 full time employees throughout the world. Most of the Company's employees in the United States are not covered by collective bargaining agreements except in certain U.S. mining operations of M-I SWACO and several distribution locations of Wilson. The Company considers its labor relations to be satisfactory. OFFICERS OF THE REGISTRANT (a) The names and ages of all officers of the Company, all positions and offices with the Company presently held by each person named and their business experience are stated below. Positions, unless otherwise specified, are with the Company. NAME, AGE AND POSITIONS PRINCIPAL CURRENT OCCUPATION AND OTHER SIGNIFICANT POSITIONS HELD ------------------------------------- ----------------------------------------------------------------- Doug Rock (58)....................... Chairman of the Board since February 1991, elected Chief Chairman of the Board, Chief Executive Officer in March 1989 and served as President and Chief Executive Officer, President Operating Officer since December 1987. Held various positions and Chief Operating Officer since joining the Company in June 1974, served as President of the Company's Drilco Division beginning April 1982 and was named President of the Company's Smith Tool Division in July 1985. Loren K. Carroll (61)................ President and Chief Executive Officer of M-I SWACO since March Executive Vice President of 1994, Executive Vice President since October 1992 and member of the Company, President and the Board of Directors since November 1987. Joined Company in Chief Executive Officer of December 1984 as Vice President and Chief Financial Officer and M-I SWACO served in that capacity until March 1989. Rejoined the Company in October 1992 as Executive Vice President and Chief Financial Officer. Margaret K. Dorman (41).............. Senior Vice President, Chief Financial Officer and Treasurer Senior Vice President, Chief since June 1999. Joined Company as Director of Financial Reporting Financial Officer and Treasurer in December 1995 and named Vice President, Controller and Assistant Treasurer in February 1998. Neal S. Sutton (59).................. Senior Vice President--Administration, General Counsel and Senior Vice President-- Secretary since December 1994. Joined Company as Vice President, Administration, General Secretary and General Counsel in January 1991 and named Vice Counsel and Secretary President-Administration in March 1992. Roger A. Brown (60).................. President, Smith Technologies since July 1998. Joined Company as President, Smith Technologies President, Smith Diamond Technology in April 1995. John J. Kennedy (52)................. President and Chief Executive Officer, Wilson since June 1999. President and Chief Executive Joined Company as Treasury Manager in November 1986, named Officer, Wilson Treasury Director responsible for International Operations in November 1987 and served as Treasurer beginning May 1991. Elected Vice President, Chief Accounting Officer and Treasurer in March 1994 and named Senior Vice President, Chief Financial Officer and Treasurer in April 1997. Richard A. Werner (63)............... President, Smith Services since May 1994. Joined Company as Vice President, Smith Services President and General Manager-Downhole Tools and Services in May 1991 and named Vice President and General Manager-Drilco/Servco in March 1993. Served as Vice President and General Manager-Smith Services beginning December 1993. Malcolm W. Anderson (57)............. Vice President, Human Resources since May 2004. Vice President Vice President, Human Resources of Hewlett Packard from January 2001 to April Human Resources 2004. Vice President Human Resources of Weatherford International Ltd. from April 1996 to December 2000. David R. Cobb (39)................... Vice President and Controller since July 2002. Joined Company as Vice President and Controller Assistant Controller in October 2001. Assistant Treasurer, Kent Electronics Corporation from April 1997 to September 2001. Geri D. Wilde (54)................... Vice President, Taxes since February 1998. Joined Company as Vice President, Taxes and Manager of Taxes and Payroll of M-I SWACO in December 1986 and Assistant Treasurer named Director of Taxes and Assistant Treasurer in April 1997. (b) All officers of the Company are elected annually by the Board of Directors at the meeting held immediately following the annual meeting of stockholders. They hold office until their successors are elected and qualified. There are no family relationships between the officers of the Company. 8 RISK FACTORS This document and other filings with the Securities and Exchange Commission contain "forward-looking statements", as defined in the Private Securities Litigation Reform Act of 1995. These forward-looking statements discuss the Company's outlook, financial projections, business strategies as well as various other matters. Our forward-looking statements are based on assumptions that we believe to be reasonable but that may not prove to be accurate. All of the Company's forward-looking information is, therefore, subject to risks and uncertainties that could cause actual results to differ materially from the results expected. Although it is not possible to identify all factors, these risks and uncertainties include the risk factors discussed below. Demand for our products and services is dependent upon the level of oil and natural gas exploration and development activities. The level of worldwide oil and natural gas development activities is primarily influenced by the price of oil and natural gas and price expectations. In addition to oil and natural gas prices, the following factors impact exploration and development activity and may lead to significant changes in worldwide activity levels: Overall level of global economic growth and activity; Actual and perceived changes in the supply and demand for oil and natural gas; Political stability of oil-producing countries; Finding and development costs of operations; and Decline and depletion rates for oil and natural gas wells. Changes in any of these factors could adversely impact our financial condition or results of operations. We are a multinational oilfield service company and have operations in certain countries that are inherently subject to risks of war, local economic conditions, political disruption, civil disturbance and policies that may: Disrupt oil and gas exploration and production activities and our operations; Restrict the movement of funds and other assets; Lead to U.S. government or international sanctions; and Limit access to markets. The occurrence of any of these events could adversely impact our financial condition or results of operations. 9 ITEM 2. PROPERTIES The principal facilities and properties utilized by the Company at December 31, 2004 are shown in the table below. Generally, the facilities and properties are owned by the Company. Approx. Principal Products Processed Land Bldg. Space Location or Manufactured (Acres) (sq.ft.) ------------------------------------- ------------------------------------------------------------ ------- ----------- Oilfield Products and Services Segment: Houston, Texas....................... Tubulars, surface and downhole tools, remedial products, liner hangers, diamond drill bits, drilling and fishing jars and fishing tool equipment 73 708,000 Houston, Texas....................... M-I SWACO corporate headquarters and research center 18 223,000 Ponca City, Oklahoma................. Three-cone drill bits 15 207,000 Florence, Kentucky................... Separator units, mill units, parts, screens and motors 15 145,000 Aberdeen, Scotland................... Downhole tools and remedial products 10 132,000 Greybull, Wyoming.................... Bentonite mine and processing 8,394 110,000 Tulsa, Oklahoma...................... Oilfield and industrial screening products 7 95,000 Saline di Volterra, Italy............ Three-cone drill bits 11 92,000 Edinburgh, Scotland.................. Wire cloth and oilfield screening products 3 91,400 Aberdeen, Scotland................... Downhole tools 10 91,000 Karmoy, Norway....................... Barite and bentonite processing 5 51,000 Greystone, Nevada.................... Barite mine and processing 268 50,000 Battle Mountain, Nevada.............. Barite processing 23 43,000 Provo, Utah.......................... Synthetic diamond materials 4 43,000 Nisku, Canada........................ Tubulars and drill collars 10 42,000 Zelmou, Morocco...................... Barite mine 3,954 41,000 Zavalla, Texas....................... Drilling fluid chemical products 33 36,000 Nivellas, Belgium.................... Separator units, mill units, parts, screens and motors 5 32,000 Scurelle, Italy...................... Diamond drill bits and synthetic diamond materials 4 31,000 Amelia, Louisiana.................... Barite processing 26 25,000 Spruce Grove, Canada................. Drilling fluid processing 3 24,000 Berra, Italy......................... Solids control equipment 2 24,000 Salzweld, Germany.................... Drilling fluid processing 2 23,000 Galveston, Texas..................... Barite processing 6 21,000 Macon, Georgia....................... Separator units and screens 1 18,000 Aberdeen, Scotland................... Barite and bentonite processing 2 12,000 Foss/Aberfeldy, Scotland............. Barite mine and processing 102 10,000 Grand Prairie, Canada................ Fishing and remedial services 2 9,000 Mountain Springs, Nevada............. Barite mine 900 -- Distribution Segment:: Houston, Texas....................... Pipe, valves and fittings 11 198,000 The Company considers its mines and manufacturing and processing facilities to be in good condition and adequately maintained. The Company also believes its facilities are suitable for their present and intended purposes and are adequate for the Company's current and anticipated level of operations. The Company's headquarters is located in a leased office building in Houston, Texas. The Company leases various other administrative and sales offices, as well as warehouses and service centers in the United States and other countries in which it conducts business. The Company believes that it will be able to renew and extend its property leases on terms satisfactory to the Company or, if necessary, locate substitute facilities on acceptable terms. ITEM 3. LEGAL PROCEEDINGS Information relating to various commitments and contingencies, including legal proceedings, is described in Note 17 of the Notes to Consolidated Financial Statements included elsewhere in this report on Form 10-K and is incorporated herein by reference. 10 ITEM 4. SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDER None. PART II ITEM 5. MARKET FOR THE REGISTRANT'S COMMON EQUITY, RELATED STOCKHOLDER MATTERS AND ISSUER PURCHASES OF EQUITY SECURITIES The common stock of the Company is traded on the New York Stock Exchange and the Pacific Stock Exchange. The following are the high and low sale prices for the Company's common stock as reported on the New York Stock Exchange Composite Tape for the periods indicated. 2003 COMMON STOCK 2004 COMMON STOCK --------------------------------- --------------------------------- Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 ------ ------ ------ ------ ------ ------ ------ ------ High $36.48 $41.55 $39.30 $42.52 $54.71 $57.75 $61.42 $62.50 Low $29.85 $34.47 $33.96 $35.86 $40.27 $48.05 $52.18 $53.98 On March 8, 2005, the Company had 2,037 common stock holders of record and the last reported closing price on the New York Stock Exchange Composite Tape was $64.34. Stock Repurchases During 2001, the Company's Board of Directors authorized a share buyback program which allows for the repurchase of up to 5.0 million shares of common stock, subject to regulatory issues, market considerations and other relevant factors. During the fourth quarter of 2004, the Company repurchased an additional 0.7 million shares of common stock under the program at an aggregate cost of $38.0 million bringing the total number of shares acquired under the program to 2.9 million as of December 31, 2004. The acquired shares have been added to the Company's treasury stock holdings and may be used in the future for acquisitions or other corporate purposes. The following table summarizes the Company's repurchase activity for the three months ended December 31, 2004: Total Number of Total Number Average Shares Purchased as Number of Shares that of Shares Price Paid Part of Publicly May Yet Be Purchased Period Purchased per Share Announced Program Under the Program ---------------- ------------ ---------- ------------------- --------------------- October 1 - 31 -- $ -- -- 2,813,600 November 1 - 30 -- $ -- -- 2,813,600 December 1 - 31 693,600 $54.75 693,600 2,120,000 ------- ------ ------- --------- 4th Quarter 2004 693,600 $54.75 693,600 2,120,000 Dividend Program The Company has not paid dividends on its common stock since the first quarter of 1986. However, on February 2, 2005, the Company's Board of Directors approved a cash dividend program for stockholders and declared a quarterly cash dividend of $0.12 per share, with the first dividend payment to be made April 15, 2005 to stockholders of record on March 15, 2005. The level of future dividend payments will be at the discretion of the Board of Directors and will depend upon the Company's financial condition, earnings and cash flow from operations, the level of its capital expenditures, compliance with certain debt covenants, its future business prospects and other factors that the Board of Directors deems relevant. 11 ITEM 6. SELECTED FINANCIAL DATA FOR THE YEARS ENDED DECEMBER 31, -------------------------------------------------------------- 2004(a) 2003 2002 2001 2000 ---------- ---------- ---------- ---------- ---------- (In thousands, except per share data) STATEMENT OF OPERATIONS DATA: Revenues ................................. $4,419,015 $3,594,828 $3,170,080 $3,551,209 $2,761,014 Gross profit ............................. 1,351,939 1,075,931 918,302 1,045,804 745,169 Operating income ......................... 438,764 328,747 256,148 371,510 199,026 Income before cumulative effect of change in accounting principle ..... 182,451 124,634 93,189 152,145 72,800 Earnings per share before cumulative effect of change in accounting principle - diluted basis (b) ......... 1.78 1.24 0.93 1.51 0.72 BALANCE SHEET DATA: Total assets ............................. $3,506,778 $3,097,047 $2,749,545 $2,735,828 $2,295,287 Long-term debt ........................... 387,798 488,548 441,967 538,842 374,716 Total stockholders' equity ............... 1,400,811 1,235,776 1,063,535 949,159 817,481 The Notes to Consolidated Financial Statements and Management's Discussion and Analysis of Financial Condition and Results of Operations included elsewhere in this Form 10-K should be read in order to understand factors such as changes in the method of accounting for goodwill, business combinations completed during 2004, 2003 and 2002, and unusual items which may affect the comparability of the information shown above. (a) In 2004, the Company recognized a $31.4 million, or $0.20 per share after tax, charge related to a patent infringement lawsuit. (b) All fiscal years prior to 2002 have been restated for the impact of a two-for-one stock split, which was effective July 8, 2002. 12 ITEM 7. MANAGEMENT'S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS GENERAL The following "Management's Discussion and Analysis of Financial Condition and Results of Operations" is provided to assist readers in understanding the Company's financial performance during the periods presented and significant trends which may impact the future performance of the Company. This discussion should be read in conjunction with the consolidated financial statements of the Company and the related notes thereto included elsewhere in this Form 10-K. COMPANY PRODUCTS AND OPERATIONS The Company manufactures and markets premium products and services to the oil and gas exploration and production industry, the petrochemical industry and other industrial markets. The Company provides a comprehensive line of technologically-advanced products and engineering services, including drilling and completion fluid systems, solids-control and separation equipment, waste-management services, oilfield production chemicals, three-cone and diamond drill bits, turbine products, fishing services, drilling tools, underreamers, casing exit and multilateral systems, packers and liner hangers. The Company also offers supply chain management solutions through an extensive North American branch network providing pipe, valves and fittings as well as mill, safety and other maintenance products. The Company's operations are largely driven by the level of exploration and production ("E&P") spending in major energy-producing regions around the world and the depth and complexity of these projects. Although E&P spending is significantly influenced by the market price of oil and natural gas, it may also be affected by supply and demand fundamentals, finding and development costs, decline and depletion rates, political actions and uncertainties, environmental concerns, the financial condition of independent E&P companies and the overall level of global economic growth and activity. In addition, approximately 10 percent of the Company's consolidated revenues relate to the downstream energy sector, including petrochemical plants and refineries, whose spending is largely impacted by the general condition of the U.S. economy. Capital investment by energy companies is largely divided into two markets which vary greatly in terms of primary business drivers and associated volatility levels. North American drilling activity is primarily influenced by natural gas fundamentals, with approximately 85 percent of the current rig count focused on natural gas finding and development activities. Conversely, drilling in areas outside of North America is more dependent on crude oil fundamentals, which influence over three-quarters of international drilling activity. Historically, business in markets outside of North America has proved to be less volatile as the high cost E&P programs in these regions are generally undertaken by major oil companies, consortiums and national oil companies as part of a longer-term strategic development plan. Although over half of the Company's consolidated revenues were generated in North America during 2004, Smith's profitability was largely dependent upon business levels in markets outside of North America. The Distribution segment, which accounts for approximately one-quarter of consolidated revenues and primarily supports a North American customer base, serves to distort the geographic revenue mix of the Company's Oilfield segment operations. Excluding the impact of the Distribution operations, 59 percent of the Company's 2004 revenues were generated in markets outside of North America. BUSINESS OUTLOOK Average worldwide activity levels grew 12 percent in 2004, as higher commodity prices influenced natural gas drilling - particularly in the U.S. land-based market. The global rig count is expected to increase modestly in 2005, as exploration and production companies focus on higher-reserve projects in the U.S. Gulf of Mexico, Europe/Africa and the Middle East markets. In addition to the anticipated increase in drilling activity and the more favorable product mix which could result from a recovery in the U.S. deepwater market, recently announced price increases in our Oilfield segment businesses could also influence near-term financial results. Although a number of factors impact drilling activity levels, our business is highly dependent on the general economic environment in the United States and other major world economies - which ultimately impact energy consumption and the resulting demand for our products and services. A significant deterioration in the global economic environment could adversely impact worldwide drilling activity and the future financial results of the Company. 13 FORWARD-LOOKING STATEMENTS This discussion contains forward-looking statements within the meaning of the Private Securities Litigation Reform Act of 1995 concerning, among other things, the Company's outlook, financial projections and business strategies, all of which are subject to risks, uncertainties and assumptions. These forward-looking statements are identified by their use of terms such as "anticipate," "believe," "could," "estimate," "expect," "project" and similar terms. The statements are based on certain assumptions and analyses made by the Company that it believes are appropriate under the circumstances. Such statements are subject to general economic and business conditions, industry conditions, changes in laws or regulations and other risk factors outlined elsewhere in this Form 10-K, many of which are beyond the control of the Company. Should one or more of these risks or uncertainties materialize, or should the assumptions prove incorrect, actual results may vary. 14 RESULTS OF OPERATIONS Segment Discussion The Company markets its products and services throughout the world through four business units which are aggregated into two reportable segments. The Oilfield Products and Services segment consists of three business units: M-I SWACO, Smith Technologies and Smith Services. The Distribution segment includes the Wilson business unit. The revenue discussion below has been summarized by business unit in order to provide additional information in analyzing the Company's operations. FOR THE YEARS ENDED DECEMBER 31, ------------------------------------------------------ 2004 2003 2002 ---------------- ---------------- ---------------- AMOUNT % AMOUNT % AMOUNT % ---------- --- ---------- --- ---------- --- FINANCIAL DATA: (dollars in thousands) REVENUES: M-I SWACO .......................... $2,231,884 50 $1,865,851 52 $1,558,672 49 Smith Technologies ................. 511,410 12 403,261 11 324,735 10 Smith Services ..................... 493,045 11 409,162 11 399,502 13 ---------- --- ---------- --- ---------- --- Oilfield Products and Services .. 3,236,339 73 2,678,274 74 2,282,909 72 Wilson ............................. 1,182,676 27 916,554 26 887,171 28 ---------- --- ---------- --- ---------- --- Total ........................ $4,419,015 100 $3,594,828 100 $3,170,080 100 ========== === ========== === ========== === GEOGRAPHIC REVENUES: United States: Oilfield Products and Services .. $1,128,294 26 $ 925,148 26 $ 813,946 26 Distribution .................... 854,173 19 667,095 18 678,764 21 ---------- --- ---------- --- ---------- --- Total United States .......... 1,982,467 45 1,592,243 44 1,492,710 47 ---------- --- ---------- --- ---------- --- Canada: Oilfield Products and Services .. 225,629 5 171,653 5 117,014 4 Distribution .................... 261,923 6 191,221 5 169,626 5 ---------- --- ---------- --- ---------- --- Total Canada ................. 487,552 11 362,874 10 286,640 9 ---------- --- ---------- --- ---------- --- Non-North America: Oilfield Products and Services .. 1,882,416 43 1,581,483 44 1,351,949 43 Distribution .................... 66,580 1 58,228 2 38,781 1 ---------- --- ---------- --- ---------- --- Total Non-North America ...... 1,948,996 44 1,639,711 46 1,390,730 44 ---------- --- ---------- --- ---------- --- Total Revenue ............. $4,419,015 100 $3,594,828 100 $3,170,080 100 ========== === ========== === ========== === OPERATING INCOME: Oilfield Products and Services ..... $ 423,648 13 $ 343,486 13 $ 266,692 12 Distribution ....................... 26,513 2 (7,897) -- (4,026) -- General Corporate .................. (11,397) * (6,842) * (6,518) * ---------- --- ---------- --- ---------- --- Total ........................ $ 438,764 10 $ 328,747 9 $ 256,148 8 ========== === ========== === ========== === MARKET DATA: AVERAGE WORLDWIDE RIG COUNT: (1) United States ...................... 1,417 49 1,216 47 946 43 Canada ............................. 348 12 339 13 255 12 Non-North America .................. 1,145 39 1,050 40 990 45 ---------- --- ---------- --- ---------- --- Total ........................ 2,910 100 2,605 100 2,191 100 ========== === ========== === ========== === Onshore ............................ 2,443 84 2,143 82 1,734 79 Offshore ........................... 467 16 462 18 457 21 ---------- --- ---------- --- ---------- --- Total ........................ 2,910 100 2,605 100 2,191 100 ========== === ========== === ========== === AVERAGE COMMODITY PRICES: Crude Oil ($/Bbl)(2)................ $ 41.34 $ 31.06 $ 26.08 Natural Gas ($/mcf)(3).............. 5.68 5.29 3.10 (1) Source: M-I SWACO. (2) Average West Texas Intermediate ("WTI") spot closing prices. (3) Average weekly composite spot U.S. wellhead prices. * not meaningful 15 Oilfield Products and Services Segment Revenues M-I SWACO primarily provides drilling and completion fluid systems, engineering and technical services to the oil and gas industry. Additionally, these operations provide oilfield production chemicals and manufacture and market equipment and services used for solids-control, particle separation, pressure control, rig instrumentation and waste-management. M-I SWACO is significantly influenced by spending in markets outside of North America, which contributes approximately two-thirds of the unit's revenues, and by its exposure to the U.S. offshore market, which constitutes approximately 10 percent of the revenue base. U.S. offshore drilling programs, which account for approximately four percent of the worldwide rig count, are generally more revenue-intensive than land-based projects due to the complex nature of the related drilling environment. For the year ended December 31, 2004, M-I SWACO reported revenues of $2.2 billion. The majority of the revenue increase was generated in markets outside of North America, where revenues grew 21 percent largely due to the underlying activity level increase of nine percent. Although increased investment by exploration and production companies in Latin America and the Middle East contributed to the improvement, new contract awards and increased customer demand for waste management product offerings in several major Europe/Africa markets also had a favorable impact. Approximately one-third of the year-over-year revenue growth was reported in North America, as increased customer spending related to land-based projects more than offset the impact of reduced drilling activity in the higher-margin U.S. offshore market. M-I SWACO's revenues totaled $1.9 billion for the year ended December 31, 2003, an increase of 20 percent above the prior year period. Excluding the effect of acquired operations, revenues rose 14 percent above 2002 levels impacted by increased sales volumes in markets outside of North America. On a geographic basis, increased E&P spending and new contract awards in Latin America, the Former Soviet Union and West Africa influenced the higher reported revenues. The year-over-year base revenue growth was also impacted by the significant increase in the number of North American land-based drilling programs and, to a lesser extent, a favorable customer mix in the U.S. offshore market. Smith Technologies designs, manufactures and sells three-cone drill bits, diamond drill bits and turbines for use in the oil and gas industry. Due to the nature of its product offerings, revenues for these operations typically correlate more closely to the rig count than any of the Company's other businesses. Moreover, Smith Technologies generally has the highest North American revenue exposure of the Oilfield segment units. For the year ended December 31, 2004, Smith Technologies reported revenues of $511.4 million, a 27 percent increase over the prior year level. Approximately three-quarters of the revenue growth was reported in North America, as increased activity levels impacted demand for diamond bit rentals. Additionally, increased market penetration resulting from new product designs and, to a lesser extent, improved product pricing also contributed to the revenue variance. Smith Technologies reported revenues of $403.3 million for the year ended December 31, 2003, an increase of 24 percent over the prior year. Excluding incremental revenues from businesses acquired in the latter half of 2002, base revenues were approximately 19 percent above the prior year and approximated the increase in the worldwide rig count. The year-to-year base revenue growth was generated in North America, reflecting the higher level of land-based drilling activity during 2003 and, to a lesser extent, the impact of new product introductions. Smith Services manufactures and markets products and services used in the oil and gas industry for drilling, work-over, well completion and well re-entry. Revenues for Smith Services are evenly distributed between North America and the international markets and are heavily influenced by the complexity of drilling projects, which drive demand for a wider range of its product offerings. For the year ended December 31, 2004, Smith Services reported revenues of $493.0 million, a 21 percent increase over the amount reported in the prior year. Approximately three-quarters of the revenue improvement was generated in the North American market, influenced by higher activity levels, increased demand for tubular products and to a lesser extent, incremental revenues from acquired operations. For the year ended December 31, 2003, Smith Services reported revenues of $409.2 million, a two percent increase from the prior year. The year-to-year revenue comparison was impacted by a 50 percent reduction in U.S. drill pipe product sales, which are not highly correlated to drilling activity. Excluding the impact of drill pipe sales, revenues increased seven percent above the prior year, primarily attributable to higher E&P spending in North America and certain Middle East markets. On a product basis, the majority of the core revenue growth was driven by higher demand for remedial product and service lines, including new product introductions. 16 Operating Income Operating income for the Oilfield Products and Services segment was $423.6 million, or 13.1 percent of revenues, for the year ended December 31, 2004. Excluding the impact of a $31.4 million litigation-related charge recorded during 2004, segment operating margins improved 1.3 percentage points due to gross margin expansion and, to a lesser extent, reduced operating expenses as a percentage of revenues. The gross margin improvement largely reflects increased fixed cost absorption in the Company's manufacturing operations and, to a lesser extent, the impact of price increases introduced in the drilling fluid and drill bit operations. Fiscal 2004 operating income, net of the litigation charge, increased $111.6 million over the prior year attributable to the impact of higher revenue volumes on gross profit, partially offset by growth in variable-based operating expenses associated with the expanding business base. For the year ended December 31, 2003, Oilfield operating income was $343.5 million, or 12.8 percent of revenues. Segment operating margins increased one percentage point above the prior year level reflecting a combination of gross margin expansion and, to a lesser extent, reduced operating expenses as a percentage of revenues. The gross margins were influenced by a favorable shift in the revenue mix towards higher-margin products and, to a lesser extent, improved expense coverage resulting from the impact of increased sales volumes on the segment's manufacturing and service infrastructure. Distribution Segment Revenues Wilson markets pipe, valves, fittings and mill, safety and other maintenance products to energy and industrial markets, primarily through an extensive network of supply branches in the United States and Canada. The segment has the most significant North American revenue exposure of any of the Company's operations with approximately 95 percent of Wilson's 2004 revenues generated in those markets. Moreover, approximately one-third of Wilson's revenues relate to sales to the downstream energy sector, including petrochemical plants and refineries, whose spending is largely influenced by the general state of the U.S. economic environment. Additionally, certain customers in this sector utilize petroleum products as a base material and, accordingly, are adversely impacted by increases in crude oil and natural gas prices. For the year ended December 31, 2004, Wilson reported revenues totaling $1.2 billion, an increase of 29 percent from the prior year period. Two-thirds of the revenue improvement was reported in Wilson's upstream energy segment, attributable to higher North American activity levels, increased demand for tubular products and new contract awards. Wilson reported revenues of $916.6 million for the year ended December 31, 2003, three percent above the prior year. The year-over-year revenue increase was reported in the energy sector operations driven by the higher level of North American drilling and completion activity. Lower industrial sales volumes, primarily related to reduced maintenance and repair spending in the refining, petrochemical and power generation customer base impacted the reported revenue variance. Operating Income Operating income for the Distribution segment was $26.5 million, or 2.2 percent of revenues, for the year ended December 31, 2004. Excluding a charge recorded in the prior year, segment operating income increased $29.8 million above the amount reported in 2003, equating to incremental operating income of 11 percent of revenues. Incremental operating income was influenced by year-over-year improvement reported in both the energy and industrial sector operations attributable to increased coverage of fixed sales and administrative costs and, to a lesser extent, the impact of favorable pricing driven by a competitive market for tubular products. For the year ended December 31, 2003, operating income for the Distribution segment declined $3.9 million from the 2002 level, impacted by a $4.6 million charge recorded in the fourth quarter of 2003. Approximately $3.8 million of this amount was an inventory-related charge, while the remainder provided for estimated losses associated with the bankruptcy of a large industrial customer. Excluding this charge, Distribution operating results increased $0.7 million over the amount reported in 2002, equating to incremental operating income of approximately two percent of revenues. The incrementals were below those historically reported in the segment, impacted by the higher mix of project and export orders, which typically generate lower comparable margins. 17 For the periods indicated, the following table summarizes the results of operations of the Company and presents these results as a percentage of total revenues (dollars in thousands): FOR THE YEARS ENDED DECEMBER 31, ------------------------------------------------------ 2004 2003 2002 ---------------- ---------------- ---------------- AMOUNT % AMOUNT % AMOUNT % ---------- --- ---------- --- ---------- --- Revenues ............................... $4,419,015 100 $3,594,828 100 $3,170,080 100 ---------- --- ---------- --- ---------- --- Gross profit ........................... 1,351,939 31 1,075,931 30 918,302 29 Operating expenses ..................... 913,175 21 747,184 21 662,154 21 ---------- --- ---------- --- ---------- --- Operating income ....................... 438,764 10 328,747 9 256,148 8 Interest expense ....................... 38,762 1 40,964 1 40,928 1 Interest income ........................ (1,300) -- (1,973) -- (2,579) -- ---------- --- ---------- --- ---------- --- Income before income taxes, minority interests and cumulative effect of change in accounting principle ........................... 401,302 9 289,756 8 217,799 7 Income tax provision ................... 129,721 3 93,334 3 66,632 2 Minority interests ..................... 89,130 2 71,788 2 57,978 2 ---------- --- ---------- --- ---------- --- Income before cumulative effect of change in accounting principle ... 182,451 4 124,634 3 93,189 3 ---------- --- ---------- --- ---------- --- Cumulative effect of change in accounting principle, net of tax and minority interests .............. -- -- (1,154) -- -- -- ---------- --- ---------- --- ---------- --- Net income ............................. $ 182,451 4 $ 123,480 3 $ 93,189 3 ========== === ========== === ========== === 2004 versus 2003 Consolidated revenues increased to $4.4 billion for the year ended December 31, 2004, 23 percent above the prior year period. The majority of the year-over-year dollar variance was reported in the Oilfield segment attributable to a combination of higher activity levels, increased market penetration and, to a lesser extent, improved product pricing. On a geographic basis, two-thirds of the revenue improvement was reported in the Western Hemisphere as the impact of higher land-based drilling more than offset revenue reductions associated with activity declines experienced in the U.S. offshore market. Improved business volumes in the Eastern Hemisphere market also contributed to the year-over-year revenue variance, reflecting the higher number of exploration and production projects and the impact of new contract awards. Gross profit totaled $1.4 billion, or 31 percent of revenues, one percentage point above the gross profit margins generated in the comparable prior year period. Although the margin expansion was largely driven by the impact of increased sales volumes on fixed manufacturing and service infrastructure costs, a shift in the business mix toward higher-margin product offerings and improved product pricing also had a favorable effect. On an absolute dollar basis, gross profit was $276.0 million above the prior year period primarily reflecting the increased sales volumes in the Oilfield operations. Operating expenses, consisting of selling, general and administrative expenses, increased $166.0 million from the amount reported in the prior year. The operating expense growth was impacted by a $28.8 million litigation-related charge recognized during 2004 to reflect an estimated loss provision, legal fees and other costs directly associated with a patent infringement case. Excluding the charge, operating expenses, as a percentage of revenues, decreased one percentage point from the prior year period. Improved fixed cost coverage in the sales and administrative functions accounted for the majority of the operating expense percentage decline. The majority of the absolute dollar increase was 18 attributable to variable-related costs associated with the improved business volumes, including investment in personnel and infrastructure to support the expanding business operations. To a lesser extent, increased employee profit-sharing amounts directly attributable to the reported profitability levels, increased medical and casualty insurance program costs and legal fees associated with defending patent infringement lawsuits also contributed to the year-over-year operating expense growth. Net interest expense, which represents interest expense less interest income, totaled $37.5 million in 2004. Net interest expense decreased $1.5 million from the prior year reflecting lower average debt levels between the periods. The effective tax rate approximated 32 percent, which was comparable to the level reported in the prior year, but below the U.S. statutory rate. The effective tax rate was lower than the U.S. statutory rate due to the impact of M-I SWACO's U.S. partnership earnings for which the minority partner is directly responsible for its related income taxes. The Company properly consolidates the pretax income related to the minority partner's share of U.S. partnership earnings but excludes the related tax provision. Minority interests reflect the portion of the results of majority-owned operations which are applicable to the minority interest partners. Minority interests totaled $89.1 million in 2004, a $17.3 million increase from the prior year. The year-over-year increase primarily reflects the higher profitability of the M-I SWACO joint venture and, to a lesser extent, improved earnings reported by CE Franklin Ltd. 2003 versus 2002 Consolidated revenues were $3.6 billion for the year ended December 31, 2003, 13 percent above the prior year's level. The majority of the revenue growth was reported in the Company's Oilfield operations, impacted by increased worldwide drilling activity and, to a lesser extent, revenues from acquired operations. Excluding incremental revenues from acquired operations, base business revenues grew 10 percent over the prior year as demand for the Company's products and services was impacted by increased North American drilling activity as well as customer spending and new contract awards in markets outside the United States and Canada. Gross profit was $1.1 billion, 17 percent above the prior year period. The increase in gross profit reflects higher sales volumes associated with the increased worldwide activity levels. Gross profit margins for the year were 30 percent of revenues, one percentage point above the gross profit margins reported in the prior year. The gross margin improvement was primarily impacted by an increased proportion of Oilfield segment sales, which traditionally generate higher gross profit margins than the Distribution segment. To a lesser extent, a favorable shift in the product mix towards higher-margin products, including drill bits and premium drilling fluids, contributed to the margin expansion. Operating expenses, consisting of selling, general and administrative expenses, increased $85.0 million from the amount reported in 2002. The majority of the year-to-year increase was attributable to higher variable costs directly associated with the improved business volumes, as well as increased investment in people and infrastructure to support the expanding base business. To a lesser extent, the operating expense variance was impacted by incremental expenses associated with acquired operations. As a percentage of revenues, operating expenses were comparable with the prior year. Net interest expense, which represents interest expense less interest income, equaled $39.0 million in 2003. Net interest expense was relatively consistent with the prior year amount as average debt levels were comparable between the periods. The effective tax rate approximated 32 percent, which was above the 31 percent effective rate reported in the prior year, but below the U.S. statutory rate. The effective tax rate was lower than the U.S. statutory rate due to the impact of M-I SWACO's U.S. partnership earnings for which the minority partner is directly responsible for its related income taxes. The Company properly consolidates the pre-tax income related to the minority partner's share of U.S. partnership earnings but excludes the related tax provision. The effective tax rate increased one percentage point from the prior year due to a shift in the geographic mix of pre-tax income toward higher rate jurisdictions and, to a lesser extent, a lower proportion of M-I SWACO's U.S. partnership earnings. Minority interests reflect the portion of the results of majority-owned operations which are applicable to the minority interest partners. Minority interests totaled $71.8 million in 2003, a $13.8 million increase from the prior year. The increase predominantly reflects the higher profitability of the M-I SWACO joint venture during 2003. The cumulative effect of change in accounting principle included for 2003 represents the impact of the adoption of Statement of Financial Accounting Standards ("SFAS") No. 143, "Accounting for Asset Retirement Obligations." 19 LIQUIDITY AND CAPITAL RESOURCES General At December 31, 2004, cash and cash equivalents equaled $53.6 million. During 2004, the Company generated $182.2 million of cash flows from operations, which is $39.6 million above the amount reported in 2003. The improvement was attributable to increased profitability levels experienced by the Company, partially offset by higher working capital investment, particularly inventories, associated with the continued increase in worldwide drilling activity. In 2004, cash flows used in investing activities totaled $163.1 million, consisting of amounts required to fund capital expenditures and, to a lesser extent, acquisitions. The Company invested $90.8 million in property, plant and equipment, net of cash proceeds arising from certain asset disposals. Acquisition funding, which primarily related to the purchase of certain operating assets from CanFish Services and the specialty chemical assets of Fortum Oil and Gas OY, resulted in cash outflows of $72.4 million in 2004. Projected net capital expenditures for 2005 are expected to approximate $115.0 million, as higher drilling activity and an expanding business base impact the level of investment in manufacturing and rental tool equipment. Capital spending in 2005 is expected to primarily consist of spending for routine additions of property and equipment to support the Company's operations and maintenance of the Company's capital equipment base. Cash flows used in financing activities totaled $17.0 million in 2004. Operating cash flow was sufficient to fund investing activities; however amounts required to finance repurchases under the Company's share buyback program resulted in incremental borrowings under existing credit facilities. The Company's primary internal source of liquidity is cash flow generated from operations. Cash flow generated by operations is primarily influenced by the level of worldwide drilling activity, which affects profitability levels and working capital requirements. Capacity under revolving credit agreements is also available, if necessary, to fund operating or investing activities. As of December 31, 2004, the Company had $315.5 million of capacity available under its U.S revolving credit facilities for future operating or investing needs. Although the facility expires in July 2005, the Company plans to re-negotiate a new agreement during the second quarter of 2005. The Company also has revolving credit facilities in place outside of the United States, which are generally used to finance local operating needs. At year-end, the Company had available borrowing capacity of $56.3 million under the non-U.S. borrowing facilities. The Company's external sources of liquidity include debt and equity financing in the public capital markets, if needed. The Company carries an investment-grade credit rating with recognized rating agencies, generally providing the Company with access to debt markets. The Company's overall borrowing capacity is, in part, dependent on maintaining compliance with financial covenants under the various credit agreements. As of year-end, the Company was well within the covenant compliance thresholds under its various loan indentures, as amended, providing the ability to access available borrowing capacity. Management believes funds generated by operations, amounts available under existing credit facilities and external sources of liquidity will be sufficient to finance capital expenditures and working capital needs of the existing operations for the foreseeable future. On February 2, 2005, the Company's Board of Directors approved a cash dividend program for stockholders and declared a quarterly cash dividend of $0.12 per share payable in April 2005. The projected annual payout of $48.5 million is expected to be funded with cash flows from operations and, if necessary, amounts available under existing credit facilities. The level of future dividend payments will be at the discretion of the Company's Board of Directors and will depend upon the Company's financial condition, earnings, cash flows, compliance with certain debt covenants and other relevant factors. Management continues to evaluate opportunities to acquire products or businesses complementary to the Company's operations. Additional acquisitions, if they arise, may involve the use of cash or, depending upon the size and terms of the acquisition, may require debt or equity financing. The Company has previously announced the signing of a non-binding letter of intent related to the sale of Wilson Industries, Inc. ("Wilson") to CE Franklin Ltd., a publicly-traded entity in which the Company currently owns 55 percent of the outstanding common stock. The potential transaction is structured as a sale of shares of Wilson in exchange for additional shares of CE Franklin. Accordingly, the transaction would not be expected to have an impact on the Company's liquidity before certain stock sale restrictions lapse, which is expected to occur in the fourth quarter of 2005. In the event the transaction is ultimately consummated, no material book gain or loss is expected to be realized on the sale. The Company, however, has agreed to fund certain of CE Franklin's transaction-related costs, primarily professional fees, which are expected to be immaterial. And, depending on the final terms of the transaction, the Company may be required to record a tax provision on the sale which could be 20 material in relation to the quarterly tax provision, negatively impacting the recorded provision and effective tax rate in the period the transaction is consummated. The Company has not engaged in off-balance sheet financing arrangements through special purpose entities, and the consolidation of the Company's minority ownership positions would not result in an increase in reported leverage ratios. The Company has no contractual arrangements in place that could result in the issuance of additional shares of the Company's common stock at a future date other than the Company's stock option program, which is discussed in Note 1, "Summary of Significant Accounting Policies," and Note 15, "Long-Term Incentive Compensation." The Company believes that it has sufficient existing manufacturing capacity to meet current demand for its products and services. Additionally, although inflation has not had a material effect on the Company in the three most recent fiscal years, the Company has experienced increases in freight costs, steel and other commodity prices during 2004. These costs, however, do not have a significant influence on the Company's overall cost structure and the Company has generally been able to offset most of these costs through productivity gains and price increases. Contractual Obligations, Commitments and Contingencies Contractual Obligations The following table summarizes the Company's debt maturities and future minimum payments under non-cancelable operating leases having initial terms in excess of one year as of December 31, 2004 (in thousands): Amount of Commitment Expiration per Period ------------------------------------------ Less than 1-3 3-5 More than Total 1 year years years 5 years -------- --------- -------- ------- --------- Debt maturities............... $599,173 $211,375 $167,868 $ 21 $219,909 Operating lease commitments... 176,183 43,263 57,034 28,691 47,195 -------- -------- -------- ------- -------- Total......................... $775,356 $254,638 $224,902 $28,712 $267,104 ======== ======== ======== ======= ======== In the normal course of business, the Company enters into lease agreements with cancellation provisions as well as agreements with initial terms of less than one year. The costs related to these leases have been reflected in rent expense, which totaled $94.8 million in 2004, but have been appropriately excluded from the future minimum payments presented in the table above. Amounts related to commitments under capital lease agreements, as well as pension and other postretirement obligations, were immaterial for the periods presented. Standby Letters of Credit and Guarantees In the normal course of business with customers, vendors and others, the Company is contingently liable for performance under standby letters of credit and bid, performance and surety bonds. Certain of these outstanding instruments guarantee payment to insurance companies which reinsure certain liability coverages of the Company's insurance captive. Excluding the impact of these instruments, for which $15.5 million of related liabilities are reflected in the accompanying consolidated balance sheet, the Company is contingently liable for approximately $65.4 million of standby letters of credit and bid, performance and surety bonds at December 31, 2004. Management does not expect any material amounts to be drawn on these instruments. During the fourth quarter of 2004, the Company obtained a surety bond in the amount of $43.5 million in connection with its appeal of the patent infringement litigation discussed below. After taking into consideration amounts reflected in the accompanying consolidated balance sheet, the Company has a contingent liability of up to $18.2 million associated with this instrument. Management, however, does not expect any amounts to be drawn on this instrument. The Company has also provided loan guarantees related to certain joint ventures accounted for under the equity method of accounting. As the net assets and cash flows of these entities are available to satisfy obligations as they become due, management believes the likelihood is remote that the Company will be required to perform under these guarantees. The Company's estimated maximum exposure under these loan guarantees approximated $20.8 million as of December 31, 2004. 21 Insurance The Company maintains insurance coverage for various aspects of its business and operations. The Company has elected to retain a portion of losses that occur through the use of deductibles and retentions under its insurance programs. Amounts in excess of the self-insured retention levels are fully insured to limits believed appropriate for the Company's operations. Self-insurance accruals are based on claims filed and an estimate for claims incurred but not reported. While management believes that amounts accrued in the accompanying consolidated financial statements are adequate for expected liabilities arising from the Company's portion of losses, estimates of these liabilities may change as circumstances develop. Litigation Halliburton Energy Services, Inc. v. Smith International, Inc. In September 2002, the Company was served with a complaint in the U.S. District Court for the Eastern District of Texas, Sherman Division entitled Halliburton Energy Services, Inc. v. Smith International, Inc. This lawsuit is a patent infringement claim alleging that certain roller cone drill bits made by the Company infringe several U.S. patents owned by Halliburton. The case was tried in the second quarter of 2004 and ultimately the plaintiff was awarded $41.1 million, which includes the original jury assessment of $24 million, a subsequent award enhancement, attorney's fees and prejudgment interest. The Company filed a notice of appeal in the fourth quarter of 2004, and a ruling from the appellate court is not anticipated until the first quarter of 2006. Prior to the trial of the U.S. case, various infringement actions and revocation proceedings in the U.K. were consolidated in the Patents Court of the High Court of Justice of England and Wales. This consolidated proceeding is essentially a U.K. counterpart to the U.S. patent action mentioned above. The case went to trial in January 2005, and a ruling from the court is not anticipated until the second quarter of 2005. The Company is defending the allegations and seeking to invalidate the patents involved. Furthermore, outside counsel has advised the Company that any damages that could potentially be shown by the plaintiff in the U.K. case have already been satisfied in the U.S. patent action mentioned above. Although an appeal is underway related to the U.S. case, the Company is continuing to pursue other options, including possible settlement of related claims outstanding. Based on the facts and circumstances and the opinion of outside counsel, management believes that the amounts recognized by the Company reflect the best estimate of its potential loss exposure. Rose Dove Egle v. John M. Egle, et al. In April 1997, the Company acquired all of the equity interests in Tri-Tech Fishing Services, L.L.C. ("Tri-Tech") in exchange for cash consideration of approximately $20.4 million (the "Transaction"). In August 1998, the Company was added as a defendant in a First Amended Petition filed in the 15th Judicial District Court, Parish of Lafayette, Louisiana entitled Rose Dove Egle v. John M. Egle, et al. In the amended petition, the plaintiffs alleged that, due to an improper conveyance of ownership interest by the Tri-Tech majority partner prior to the Transaction, Smith purchased a portion of its equity interest from individuals who were not legally entitled to their Tri-Tech shares. The suit was tried in the first quarter of 2004, and a jury verdict of approximately $4.8 million was rendered in favor of the plaintiffs. The Company has initiated the appeal process and does not anticipate a ruling from the appellate court until the first quarter of 2006. Based upon the facts and circumstances and the opinion of outside legal counsel, management believes that an unfavorable outcome on this matter is not probable at this time. Accordingly, the Company has not recognized a loss provision in the accompanying consolidated financial statements. Other The Company is a defendant in various other legal proceedings arising in the ordinary course of business. In the opinion of management, these matters will not have a material adverse effect on the Company's consolidated financial position or results of operations. 22 Environmental The Company routinely establishes and reviews the adequacy of reserves for estimated future environmental clean-up costs for properties currently or previously operated by the Company. In connection with most business acquisitions, the Company obtains contractual indemnifications from the seller related to environmental matters. These indemnifications generally provide for the reimbursement of environmental clean-up costs incurred by the Company for events occurring or circumstances existing prior to the purchase date, whether the event or circumstance was known or unknown at that time. A substantial portion of the Company's total environmental exposure is associated with its M-I SWACO operations, which are subject to various indemnifications from former owners. As of December 31, 2004, the Company's environmental reserve totaled $9.0 million. This amount reflects the future undiscounted estimated exposure related to identified properties, without regard to indemnifications from former owners. While actual future environmental costs may differ from estimated liabilities recorded at December 31, 2004, the Company does not believe that these differences will have a material impact on the Company's financial position or results of operations, subject to the indemnifications in place. During 2003, the Company took legal action against M-I SWACO's former owners to clarify certain contractual provisions of the environmental indemnification upon which approximately $8.3 million of remediation costs properly incurred under the indemnification remains unpaid. This matter is expected to go to trial during the second quarter of 2005. In the event that (i) M-I SWACO's former owners and other parties to indemnification agreements with the Company do not fulfill their obligations, and (ii) costs incurred to remediate the identified properties reach estimated maximum exposure limits, the Company would be required to record an additional charge of up to $25.0 million, impacting earnings and cash flows in future periods. CRITICAL ACCOUNTING POLICIES AND ESTIMATES The discussion and analysis of financial condition and results of operations are based upon the Company's consolidated financial statements, which have been prepared in accordance with accounting principles generally accepted in the United States. The preparation of these financial statements requires management to make estimates and judgments that affect the reported amounts of assets, liabilities, revenues and expenses, and related disclosure of contingent assets and liabilities. The Company evaluates its estimates on an on-going basis, based on historical experience and on various other assumptions that are believed to be reasonable under the circumstances. Actual results may differ from these estimates under different assumptions or conditions. The Company believes the following describes significant judgments and estimates used in the preparation of its consolidated financial statements: Allowance for doubtful accounts. The Company extends credit to customers and other parties in the normal course of business. Management regularly reviews outstanding receivables and provides for estimated losses through an allowance for doubtful accounts. In evaluating the level of established reserves, management makes judgments regarding the parties' ability to make required payments, economic events and other factors. As the financial condition of these parties change, circumstances develop or additional information becomes available, adjustments to the allowance for doubtful accounts may be required. Inventory reserves. The Company has made significant investments in inventory to service its customers around the world. On a routine basis, the Company uses judgments in determining the level of reserves required to state inventory at the lower of cost or market. Management's estimates are primarily influenced by technological innovations, market activity levels and the physical condition of products. Changes in these or other factors may result in adjustments to the carrying value of inventory. Goodwill. The Company has acquired a number of operations during the past decade, which has resulted in the recording of a material amount of goodwill. Under SFAS No. 142, "Goodwill and Other Intangible Assets," the Company is required to perform an annual goodwill impairment evaluation, which is largely influenced by future cash flow projections. Estimating future cash flows of the Company's operations requires management to make judgments about future operating results and working capital requirements. Although the majority of the goodwill relates to the Company's Oilfield operations, $37.8 million of goodwill relates to Distribution transactions. Changes in cash flow 23 assumptions or other factors which negatively impact the fair value of the operations would influence the evaluation and may result in the determination that a portion of the goodwill is impaired when the annual analysis is performed. Self-Insurance. The Company maintains insurance coverage for various aspects of its business and operations. The Company retains a portion of losses that occur through the use of deductibles and retentions under self-insurance programs. Management regularly reviews estimates of reported and unreported claims and provides for losses through insurance reserves. As claims develop and additional information becomes available, adjustments to loss reserves may be required. Income taxes. Deferred tax assets and liabilities are recognized for differences between the book basis and tax basis of the net assets of the Company. In providing for deferred taxes, management considers current tax regulations, estimates of future taxable income and available tax planning strategies. In certain cases, management has established reserves to reduce deferred tax assets to estimated realizable value. If tax regulations, operating results or the ability to implement tax planning strategies vary, adjustments to the carrying value of deferred tax assets and liabilities may be required. Environmental Obligations. The Company records liabilities for environmental obligations when remedial efforts are probable and the costs can be reasonably estimated. Management's estimates are based on currently enacted laws and regulations. As more information becomes available or environmental laws and regulations change, such liabilities may be required to be adjusted. Additionally, in connection with acquisitions, the Company generally obtains indemnifications from the seller related to environmental matters. If the indemnifying parties do not fulfill their obligations, adjustments of recorded amounts may be required. RECENT ACCOUNTING PRONOUNCEMENTS In December 2004, the Financial Accounting Standards Board ("FASB") issued SFAS No. 123 (revised 2004), "Share-Based Payment" ("SFAS No. 123r") which replaces Statement No. 123 and supersedes Accounting Principles Board Opinion No. 25. SFAS No. 123r addresses the financial accounting and reporting of share-based payments to employees, including grants of stock options. SFAS No. 123r requires the recognition of compensation expense, which is measured based on the grant date fair value of equity awards, generally over the vesting period of the related stock option. The Company expects to adopt SFAS No. 123r effective July 1, 2005 and is evaluating the alternative transition methods allowed by the statement, including the modified prospective and limited modified retrospective methods. Under the modified prospective method, compensation cost related to all unvested stock options is recognized beginning with the effective date; however, the limited modified retrospective method permits restatement of prior periods assuming adoption of SFAS No 123r as of January 1, 2005. Although the Company continues to evaluate the standard and related transition matters, based on equity awards granted to employees through December 31, 2004 and those expected to be granted during the second quarter of 2005, share-based compensation expense on a full year basis is expected to total approximately $12.0 million, net of tax. From time to time, new accounting pronouncements are issued by the FASB which are adopted by the Company as of the specified effective date. Unless otherwise discussed, management believes the impact of recently issued standards, which are not yet effective, will not have a material impact on the Company's consolidated financial statements upon adoption. 24 ITEM 7A. QUALITATIVE AND QUANTITATIVE MARKET RISK DISCLOSURES The Company is exposed to market risks from changes in interest rates and foreign exchange rates and enters into various hedging transactions to mitigate these risks. The Company does not use financial instruments for trading or speculative purposes. See Note 10, "Financial Instruments," for additional discussion of hedging instruments. The Company's exposure to interest rate changes is managed through the use of a combination of fixed and floating rate debt and by entering into interest rate contracts, from time to time, on a portion of its long-term borrowings. The Company had no interest rate contracts outstanding as of December 31, 2004 and 2003. At December 31, 2004, 19 percent of the Company's long-term debt carried a variable interest rate. Management believes that significant interest rate changes will not have a material near-term impact on the Company's future earnings or cash flows. The Company's exposure to changes in foreign exchange rates is managed primarily through the use of forward exchange contracts. These contracts increase or decrease in value as foreign exchange rates change, to protect the value of the underlying transactions denominated in foreign currencies. All currency contracts are components of the Company's hedging program and are entered into for the sole purpose of hedging an existing or anticipated currency exposure. The gains and losses on these contracts offset changes in the value of the related exposures. The terms of these contracts generally do not exceed two years. As of December 31, 2004, the notional amount of fair value hedge contracts outstanding was $97.2 million, approximating the fair value of these contracts. As of December 31, 2003, the notional amounts of fair value hedge contracts and cash flow hedge contracts outstanding were $45.5 million and $9.2 million, respectively, and the fair value exceeded the notional amount of these contracts by $1.9 million. In some areas, where hedging is not cost effective, the Company addresses foreign currency exposure utilizing working capital management. The Company utilizes a "Value-at-Risk" ("VAR") model to determine the maximum potential one-day loss in the fair value of its foreign exchange sensitive financial instruments. The VAR model estimates were made assuming normal market conditions and a 95 percent confidence level. The Company's VAR computations are based on the historical price movements in various currencies (a "historical" simulation) during the year. The model includes all of the Company's foreign exchange derivative contracts. Anticipated transactions, firm commitments and assets and liabilities denominated in foreign currencies, which certain of these instruments are intended to hedge, were excluded from the model. The VAR model is a risk analysis tool and does not purport to represent actual losses in fair value that will be incurred by the Company, nor does it consider the potential effect of favorable changes in market factors. The estimated maximum potential one-day loss in fair value of currency sensitive instruments, calculated using the VAR model, was not material to the Company's financial position or results of operations. 25 ITEM 8. FINANCIAL STATEMENTS AND SUPPLEMENTARY DATA MANAGEMENT'S REPORT ON INTERNAL CONTROL OVER FINANCIAL REPORTING Management of the Company is responsible for establishing and maintaining effective internal control over financial reporting as defined in Rule 13a - 15(f) under the Securities Exchange Act of 1934. The Company's internal control over financial reporting is designed to provide reasonable, not absolute, assurance to the Company's management and board of directors regarding the preparation and fair presentation of published financial statements. Because of its inherent limitations, internal control over financial reporting may not prevent or detect misstatements. Therefore, even those systems determined to be effective can provide only reasonable, not absolute, assurance with respect to financial statement preparation and presentation. The Company's management assessed the effectiveness of the Company's internal control over financial reporting based on criteria established in Internal Control--Integrated Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission. Based on this assessment, management believes that the Company's internal control over financial reporting was effective as of December 31, 2004. Management's assessment of the effectiveness of internal control over financial reporting as of December 31, 2004 has been audited by Deloitte & Touche LLP, the independent registered public accounting firm who also audited the Company's consolidated financial statements. The Deloitte & Touche LLP attestation report on management's assessment of the Company's internal control over financial reporting appears on page 27 of this Annual Report on Form 10-K. /s/ DOUG ROCK /s/ LOREN K. CARROLL /s/ MARGARET K. DORMAN --------------------------- ------------------------ ----------------------- Doug Rock Loren K. Carroll Margaret K. Dorman Chairman of the Board and Executive Vice President Senior Vice President, Chief Executive Officer Chief Financial Officer and Treasurer 26 REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM To the Board of Directors and Stockholders of Smith International, Inc.: We have audited management's assessment, included in the accompanying Management's Report on Internal Control Over Financial Reporting, that Smith International, Inc. and subsidiaries (the "Company") maintained effective internal control over financial reporting as of December 31, 2004, based on criteria established in Internal Control--Integrated Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission. The Company's management is responsible for maintaining effective internal control over financial reporting and for its assessment of the effectiveness of internal control over financial reporting. Our responsibility is to express an opinion on management's assessment and an opinion on the effectiveness of the Company's internal control over financial reporting based on our audit. We conducted our audit in accordance with the standards of the Public Company Accounting Oversight Board (United States). Those standards require that we plan and perform the audit to obtain reasonable assurance about whether effective internal control over financial reporting was maintained in all material respects. Our audit included obtaining an understanding of internal control over financial reporting, evaluating management's assessment, testing and evaluating the design and operating effectiveness of internal control, and performing such other procedures as we considered necessary in the circumstances. We believe that our audit provides a reasonable basis for our opinions. A company's internal control over financial reporting is a process designed by, or under the supervision of, the company's principal executive and principal financial officers, or persons performing similar functions, and effected by the company's board of directors, management, and other personnel to provide reasonable assurance regarding the reliability of financial reporting and the preparation of financial statements for external purposes in accordance with generally accepted accounting principles. A company's internal control over financial reporting includes those policies and procedures that (1) pertain to the maintenance of records that, in reasonable detail, accurately and fairly reflect the transactions and dispositions of the assets of the company; (2) provide reasonable assurance that transactions are recorded as necessary to permit preparation of financial statements in accordance with generally accepted accounting principles, and that receipts and expenditures of the company are being made only in accordance with authorizations of management and directors of the company; and (3) provide reasonable assurance regarding prevention or timely detection of unauthorized acquisition, use, or disposition of the company's assets that could have a material effect on the financial statements. Because of the inherent limitations of internal control over financial reporting, including the possibility of collusion or improper management override of controls, material misstatements due to error or fraud may not be prevented or detected on a timely basis. Also, projections of any evaluation of the effectiveness of the internal control over financial reporting to future periods are subject to the risk that the controls may become inadequate because of changes in conditions, or that the degree of compliance with the policies or procedures may deteriorate. In our opinion, management's assessment that the Company maintained effective internal control over financial reporting as of December 31, 2004, is fairly stated, in all material respects, based on the criteria established in Internal Control--Integrated Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission. Also in our opinion, the Company maintained, in all material respects, effective internal control over financial reporting as of December 31, 2004, based on the criteria established in Internal Control--Integrated Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission. We have also audited, in accordance with the standards of the Public Company Accounting Oversight Board (United States), the consolidated financial statements as of and for the year ended December 31, 2004 of the Company and our report dated March 14, 2005 expressed an unqualified opinion on those financial statements. DELOITTE & TOUCHE LLP Houston, Texas March 14, 2005 27 REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM To the Board of Directors and Stockholders of Smith International, Inc.: We have audited the accompanying consolidated balance sheets of Smith International, Inc. and subsidiaries (the "Company") as of December 31, 2004 and 2003, and the related consolidated statements of operations, stockholders' equity, and comprehensive income, and cash flows for each of the three years in the period ended December 31, 2004. Our audits also included the financial statement schedule listed in Part IV, Item 15 (a) (2). These financial statements and the financial statement schedule are the responsibility of the Company's management. Our responsibility is to express an opinion on the financial statements and financial statement schedule based on our audits. We conducted our audits in accordance with the standards of the Public Company Accounting Oversight Board (United States). Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements. An audit also includes assessing the accounting principles used and significant estimates made by management, as well as evaluating the overall financial statement presentation. We believe that our audits provide a reasonable basis for our opinion. In our opinion, such consolidated financial statements present fairly, in all material respects, the financial position of Smith International, Inc. and subsidiaries as of December 31, 2004 and 2003, and the results of their operations and their cash flows for each of the three years in the period ended December 31, 2004, in conformity with accounting principles generally accepted in the United States of America. Also, in our opinion, such financial statement schedule, when considered in relation to the basic consolidated financial statements taken as a whole, presents fairly, in all material respects, the information set forth therein. We have also audited, in accordance with the standards of the Public Company Accounting Oversight Board (United States), the effectiveness of the Company's internal control over financial reporting as of December 31, 2004, based on the criteria established in Internal Control--Integrated Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission and our report dated March 14, 2005 expressed an unqualified opinion on management's assessment of the effectiveness of the Company's internal control over financial reporting and an unqualified opinion on the effectiveness of the Company's internal control over financial reporting. As discussed in Note 3 to the financial statements, the Company adopted the provisions of Statement of Financial Accounting Standards No. 143, "Accounting for Asset Retirement Obligations" in 2003. DELOITTE & TOUCHE LLP Houston, Texas March 14, 2005 28 SMITH INTERNATIONAL, INC. CONSOLIDATED BALANCE SHEETS (In thousands, except par value data) DECEMBER 31, ----------------------- 2004 2003 ---------- ---------- ASSETS CURRENT ASSETS: Cash and cash equivalents ....................................................... $ 53,596 $ 51,286 Receivables, net (Note 1) ....................................................... 963,622 801,819 Inventories, net ................................................................ 890,462 739,627 Deferred tax assets, net ........................................................ 47,083 31,238 Prepaid expenses and other ...................................................... 64,869 55,826 ---------- ---------- Total current assets ......................................................... 2,019,632 1,679,796 ---------- ---------- PROPERTY, PLANT AND EQUIPMENT, NET ................................................. 576,954 534,871 GOODWILL, NET ...................................................................... 713,353 690,593 OTHER INTANGIBLE ASSETS, NET ....................................................... 68,597 65,179 OTHER ASSETS ....................................................................... 128,242 126,608 ---------- ---------- TOTAL ASSETS ....................................................................... $3,506,778 $3,097,047 ========== ========== LIABILITIES AND STOCKHOLDERS' EQUITY CURRENT LIABILITIES: Short-term borrowings and current portion of long-term debt ..................... $ 211,375 $ 89,747 Accounts payable ................................................................ 376,782 310,754 Accrued payroll costs ........................................................... 89,200 73,723 Income taxes payable ............................................................ 91,587 69,301 Other ........................................................................... 118,413 87,399 ---------- ---------- Total current liabilities .................................................... 887,357 630,924 ---------- ---------- LONG-TERM DEBT ..................................................................... 387,798 488,548 DEFERRED TAX LIABILITIES ........................................................... 93,777 80,065 OTHER LONG-TERM LIABILITIES ........................................................ 82,352 74,066 MINORITY INTERESTS ................................................................. 654,683 587,668 COMMITMENTS AND CONTINGENCIES (Note 17) STOCKHOLDERS' EQUITY: Preferred stock, $1 par value; 5,000 shares authorized; no shares issued or outstanding in 2004 or 2003 ........................................ -- -- Common stock, $1 par value; 150,000 shares authorized; 105,297 shares issued in 2004 (102,720 shares issued in 2003) ............................... 105,297 102,720 Additional paid-in capital ...................................................... 432,395 371,438 Retained earnings ............................................................... 961,574 779,123 Accumulated other comprehensive income .......................................... 24,404 11,625 Less - Treasury securities, at cost; 4,222 common shares in 2004 (2,384 common shares in 2003) ................................................ (122,859) (29,130) ---------- ---------- Total stockholders' equity ................................................... 1,400,811 1,235,776 ---------- ---------- TOTAL LIABILITIES AND STOCKHOLDERS' EQUITY ......................................... $3,506,778 $3,097,047 ========== ========== The accompanying notes are an integral part of these financial statements. 29 SMITH INTERNATIONAL, INC. CONSOLIDATED STATEMENTS OF OPERATIONS (In thousands, except per share data) FOR THE YEARS ENDED DECEMBER 31, ------------------------------------ 2004 2003 2002 ---------- ---------- ---------- Revenues ................................................. $4,419,015 $3,594,828 $3,170,080 Costs and expenses: Costs of revenues ..................................... 3,067,076 2,518,897 2,251,778 Selling expenses ...................................... 685,272 586,163 520,509 General and administrative expenses ................... 227,903 161,021 141,645 ---------- ---------- ---------- Total costs and expenses ........................... 3,980,251 3,266,081 2,913,932 ---------- ---------- ---------- Operating income ......................................... 438,764 328,747 256,148 Interest expense ......................................... 38,762 40,964 40,928 Interest income .......................................... (1,300) (1,973) (2,579) ---------- ---------- ---------- Income before income taxes, minority interests and cumulative effect of change in accounting principle ............................................. 401,302 289,756 217,799 Income tax provision ..................................... 129,721 93,334 66,632 Minority interests ....................................... 89,130 71,788 57,978 ---------- ---------- ---------- Income before cumulative effect of change in accounting principle .................................. 182,451 124,634 93,189 Cumulative effect of change in accounting principle, net of tax and minority interests ..................... -- (1,154) -- ---------- ---------- ---------- Net income ............................................... $ 182,451 $ 123,480 $ 93,189 ========== ========== ========== Basic: Earnings per share before cumulative effect of change in accounting principle ..................... $ 1.80 $ 1.25 $ 0.94 Cumulative effect of change in accounting principle, net of tax and minority interests .................. -- (0.01) -- ---------- ---------- ---------- Earnings per share .................................... $ 1.80 $ 1.24 $ 0.94 ========== ========== ========== Diluted: Earnings per share before cumulative effect of change in accounting principle ..................... $ 1.78 $ 1.24 $ 0.93 Cumulative effect of change in accounting principle, net of tax and minority interests .................. -- (0.01) -- ---------- ---------- ---------- Earnings per share .................................... $ 1.78 $ 1.23 $ 0.93 ========== ========== ========== Weighted average shares outstanding: Basic ................................................. 101,332 99,815 98,984 Diluted ............................................... 102,569 100,903 100,091 The accompanying notes are an integral part of these financial statements. 30 SMITH INTERNATIONAL, INC. CONSOLIDATED STATEMENTS OF CASH FLOWS (In thousands) FOR THE YEARS ENDED DECEMBER 31, --------------------------------- 2004 2003 2002 --------- --------- --------- CASH FLOWS FROM OPERATING ACTIVITIES: Net income .............................................................. $ 182,451 $ 123,480 $ 93,189 Adjustments to reconcile net income to net cash provided by operating activities, excluding the net effects of acquisitions: Depreciation and amortization ........................................ 106,493 101,709 89,327 Minority interests ................................................... 89,130 71,788 57,978 Deferred income tax provision (benefit) .............................. (1,764) 8,154 23,560 Provision for losses on receivables .................................. 3,846 3,835 9,593 Increase in LIFO inventory reserves .................................. 28,177 231 439 Gain on disposal of property, plant and equipment .................... (10,592) (8,463) (4,645) Foreign currency translation losses (gains) .......................... 1,790 1,516 (864) Cumulative effect of change in accounting principle .................. -- 1,154 -- Litigation-related charge ............................................ 31,439 -- -- Changes in operating assets and liabilities: Receivables .......................................................... (153,066) (161,205) 119,600 Inventories .......................................................... (167,879) (90,167) 33,675 Accounts payable ..................................................... 61,669 49,452 (32,817) Other current assets and liabilities ................................. 21,937 46,001 (48,339) Other non-current assets and liabilities ............................. (11,457) (4,903) (17,170) --------- --------- --------- Net cash provided by operating activities ......................... 182,174 142,582 323,526 --------- --------- --------- CASH FLOWS FROM INVESTING ACTIVITIES: Acquisitions, net of cash acquired ................................... (72,350) (101,789) (60,152) Purchases of property, plant and equipment ........................... (111,449) (98,923) (97,051) Proceeds from disposal of property, plant and equipment .............. 20,679 22,902 18,247 Other ................................................................ -- -- (231) --------- --------- --------- Net cash used in investing activities ............................. (163,120) (177,810) (139,187) --------- --------- --------- CASH FLOWS FROM FINANCING ACTIVITIES: Proceeds from issuance of long-term debt ............................. 68,858 116,615 15,902 Principal payments of long-term debt ................................. (85,832) (135,499) (130,775) Net change in short-term borrowings .................................. 54,114 2,014 (1,170) Purchases of treasury stock .......................................... (92,002) -- -- Proceeds from employee stock option exercises ........................ 61,016 18,958 5,047 Distributions to minority interest partner ........................... (23,200) (4,000) (31,600) --------- --------- --------- Net cash used in financing activities ............................. (17,046) (1,912) (142,596) --------- --------- --------- Effect of exchange rate changes on cash ................................. 302 1,676 324 --------- --------- --------- Increase (decrease) in cash and cash equivalents ........................ 2,310 (35,464) 42,067 Cash and cash equivalents at beginning of year .......................... 51,286 86,750 44,683 --------- --------- --------- Cash and cash equivalents at end of year ................................ $ 53,596 $ 51,286 $ 86,750 ========= ========= ========= SUPPLEMENTAL DISCLOSURES OF CASH FLOW INFORMATION: Cash paid for interest .................................................. $ 38,158 $ 41,306 $ 41,150 Cash paid for income taxes .............................................. 111,568 50,980 39,743 The accompanying notes are an integral part of these financial statements. 31 SMITH INTERNATIONAL, INC. CONSOLIDATED STATEMENTS OF STOCKHOLDERS' EQUITY AND COMPREHENSIVE INCOME FOR THE YEARS ENDED DECEMBER 31, 2004, 2003 AND 2002 (IN THOUSANDS, EXCEPT SHARE DATA) COMMON STOCK ACCUMULATED ---------------------- ADDITIONAL OTHER NUMBER OF PAID-IN RETAINED COMPREHENSIVE SHARES AMOUNT CAPITAL EARNINGS INCOME ----------- -------- ---------- -------- ------------- Balance, January 1, 2002 ................................ 50,593,930 $ 50,594 $389,989 $562,454 $(24,748) Comprehensive income: Net income ........................................ -- -- -- 93,189 -- Currency translation adjustments .................. -- -- -- -- 13,597 Changes in unrealized fair value of derivatives ... -- -- -- -- 3,266 Minimum pension liability adjustments ............. -- -- -- -- (2,550) ----------- -------- -------- -------- -------- Comprehensive income .................................... -- -- -- 93,189 14,313 Exercise of stock options and stock grants .............. 276,993 277 6,597 -- -- Two-for-one common stock split (Note 12) ................ 50,675,019 50,675 (50,675) -- -- ----------- -------- -------- -------- -------- Balance, December 31, 2002 .............................. 101,545,942 101,546 345,911 655,643 (10,435) Comprehensive income: Net income ........................................ -- -- -- 123,480 -- Currency translation adjustments .................. -- -- -- -- 22,073 Changes in unrealized fair value of derivatives ... -- -- -- -- 36 Minimum pension liability adjustments ............. -- -- -- -- (49) ----------- -------- -------- -------- -------- Comprehensive income .................................... -- -- -- 123,480 22,060 Exercise of stock options and stock grants .............. 1,174,364 1,174 25,527 -- -- ----------- -------- -------- -------- -------- Balance, December 31, 2003 .............................. 102,720,306 102,720 371,438 779,123 11,625 Comprehensive income: Net income ........................................ -- -- -- 182,451 -- Currency translation adjustments .................. -- -- -- -- 14,963 Changes in unrealized fair value of derivatives ... -- -- -- -- (2,471) Minimum pension liability adjustments ................ -- -- -- -- 287 ----------- -------- -------- -------- -------- Comprehensive income .................................... -- -- -- 182,451 12,779 Purchases of treasury stock ............................. -- -- -- -- -- Exercise of stock options and stock grants .............. 2,576,347 2,577 60,957 -- -- ----------- -------- -------- -------- -------- Balance, December 31, 2004 .............................. 105,296,653 $105,297 $432,395 $961,574 $ 24,404 =========== ======== ======== ======== ======== TREASURY SECURITIES ---------------------- COMMON STOCK ---------------------- TOTAL NUMBER OF STOCKHOLDERS' SHARES AMOUNT EQUITY ---------- --------- ------------- Balance, January 1, 2002 ................................ (1,192,054) $ (29,130) $ 949,159 Comprehensive income: Net income ........................................ -- -- 93,189 Currency translation adjustments .................. -- -- 13,597 Changes in unrealized fair value of derivatives ... -- -- 3,266 Minimum pension liability adjustments ............. -- -- (2,550) ---------- --------- ---------- Comprehensive income .................................... -- -- 107,502 Exercise of stock options and stock grants .............. -- -- 6,874 Two-for-one common stock split (Note 12) ................ (1,192,054) -- -- ---------- --------- ---------- Balance, December 31, 2002 .............................. (2,384,108) (29,130) 1,063,535 Comprehensive income: Net income ........................................ -- -- 123,480 Currency translation adjustments .................. -- -- 22,073 Changes in unrealized fair value of derivatives ... -- -- 36 Minimum pension liability adjustments ............. -- -- (49) ---------- --------- ---------- Comprehensive income .................................... -- -- 145,540 Exercise of stock options and stock grants .............. -- -- 26,701 ---------- --------- ---------- Balance, December 31, 2003 .............................. (2,384,108) (29,130) 1,235,776 Comprehensive income: Net income ........................................ -- -- 182,451 Currency translation adjustments .................. -- -- 14,963 Changes in unrealized fair value of derivatives ... -- -- (2,471) Minimum pension liability adjustments ................ -- -- 287 ---------- --------- ---------- Comprehensive income .................................... -- -- 195,230 Purchases of treasury stock ............................. (1,807,600) (92,002) (92,002) Exercise of stock options and stock grants .............. (30,758) (1,727) 61,807 ---------- --------- ---------- Balance, December 31, 2004 .............................. (4,222,466) $(122,859) $1,400,811 ========== ========= ========== The accompanying notes are an integral part of these financial statements. 32 SMITH INTERNATIONAL, INC. NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (All dollar amounts are expressed in thousands, unless otherwise noted) 1. SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES Basis of Presentation Smith International, Inc. ("Smith" or the "Company") provides premium products and services to the oil and gas exploration and production industry, the petrochemical industry and other industrial markets. The accompanying consolidated financial statements were prepared in accordance with accounting principles generally accepted in the United States and all applicable financial statement rules and regulations of the Securities and Exchange Commission (the "Commission"). Management believes the consolidated financial statements present fairly the financial position, results of operations and cash flows of the Company as of the dates indicated. The consolidated financial statements include the accounts of the Company and all wholly and majority-owned subsidiaries, after the elimination of all significant intercompany accounts and transactions. Investments in affiliates in which ownership interest ranges from 20 to 50 percent, and the Company exercises significant influence over operating and financial policies, are accounted for on the equity method. All other investments are carried at cost, which does not exceed the estimated net realizable value of such investments. Certain reclassifications have been made to the prior years' financial information to conform to the 2004 presentation. Use of Estimates Preparation of financial statements in conformity with accounting principles generally accepted in the United States requires management to make estimates and assumptions that affect the reported amounts of assets and liabilities, the disclosed amounts of contingent assets and liabilities and the reported amounts of revenues and expenses. Management believes the most significant estimates and assumptions are associated with the valuation of accounts receivable, inventories, goodwill and deferred taxes as well as the determination of liabilities related to environmental obligations and self-insurance programs. If the underlying estimates and assumptions, upon which the financial statements are based, change in future periods, actual amounts may differ from those included in the accompanying consolidated financial statements. Cash and Cash Equivalents The Company considers all highly liquid financial instruments purchased with an original maturity of three months or less to be cash equivalents. Allowance for Doubtful Accounts The Company maintains an allowance for doubtful accounts to provide for receivables which may ultimately be uncollectible. Reserves are determined in light of a number of factors including customer specific conditions, economic events and the Company's historical loss experience. At December 31, 2004 and 2003, the allowance for doubtful accounts was $12.6 million and $12.1 million, respectively. Inventories Inventories are stated at the lower of cost or market. Cost is determined using the average cost method for the majority of the Company's inventories; however, certain of the Company's U.S.-based inventories are valued utilizing the last-in, first-out ("LIFO") method. Inventory costs consist of materials, labor and factory overhead. 33 Fixed Assets Fixed assets, consisting of rental equipment and property, plant and equipment, are stated at cost, net of accumulated depreciation. The Company computes depreciation on fixed assets using principally the straight-line method; however, for income tax purposes, accelerated methods of depreciation are used. The estimated useful lives used in computing depreciation generally range from 20 to 40 years for buildings, three to 25 years for machinery and equipment, and five to ten years for rental equipment. Leasehold improvements are amortized over the initial lease term or the estimated useful lives of the improvements, whichever is shorter. Depreciation expense for the years ended December 31, 2004, 2003 and 2002 was $96.9 million, $93.5 million and $84.7 million, respectively. Costs of major renewals and betterments are capitalized as fixed assets; however, expenditures for maintenance, repairs and minor improvements are charged to expense when incurred. When fixed assets are sold or retired, the remaining cost and related accumulated depreciation are removed from the accounts and the resulting gain or loss is included in the consolidated statement of operations. Goodwill and Other Intangible Assets Goodwill represents the excess of cost over the fair value of net assets acquired. In accordance with Statement of Financial Accounting Standards ("SFAS") No. 142, "Goodwill and Other Intangible Assets," recorded goodwill balances are not amortized but, instead, are evaluated for impairment annually or more frequently if circumstances indicate that an impairment may exist. The goodwill valuation, which is prepared during the first quarter of each calendar year, is largely influenced by projected future cash flows and, therefore, is significantly impacted by estimates and judgments. The Company amortizes other identifiable intangible assets on a straight-line basis over the periods expected to be benefited, ranging from three to 27 years. The components of these other intangible assets, recorded in other assets in the accompanying consolidated balance sheets generally consist of patents, license agreements, non-compete agreements, trademarks and customer lists and contracts. Impairment of Long-Lived Assets Management reviews long-lived assets for impairment whenever events or changes in circumstances indicate that the carrying amount may not be recoverable. If an evaluation is required, the estimated undiscounted future cash flows associated with the asset will be compared to the asset's carrying amount to determine if an impairment exists. Environmental Obligations Expenditures for environmental obligations that relate to current operations are expensed or capitalized, as appropriate. Liabilities are recorded when environmental clean-up efforts are probable and their cost is reasonably estimated, and are adjusted as further information is obtained. Such estimates are based on currently enacted laws and regulations and are not discounted to present value. Liabilities Related to Self-Insurance Programs The Company is self-insured for certain casualty and employee medical insurance liabilities of its U.S. operations. Expenditures for casualty and medical claims are recorded when incurred after taking into consideration recoveries available under stop-loss insurance policies. Additionally, reserves are established to provide for the estimated cost of settling known claims as well as medical and casualty exposures projected to have been incurred but not yet reported. Foreign Currency Translation and Transactions Gains and losses resulting from balance sheet translation of operations outside the United States where the applicable foreign currency is the functional currency are included as a component of accumulated other comprehensive income within stockholders' equity. Gains and losses resulting from balance sheet translation of operations outside the United States where the U.S. dollar is the functional currency are included in the consolidated statements of operations. Gains and losses resulting from foreign currency transactions, excluding cash flow hedges discussed below, are recognized currently in the consolidated statements of operations. 34 Financial Instruments The nature of the Company's business activities involves the management of various financial and market risks, including those related to changes in currency exchange rates and interest rates. The Company utilizes derivative financial instruments such as foreign exchange contracts, foreign exchange options and interest rate contracts to mitigate or eliminate certain of those risks. The Company does not enter into derivative instruments for speculative purposes. The Company records changes in fair market value related to fair value hedges, which includes foreign exchange contracts, to general and administrative expenses in the consolidated statements of operations. Changes in value related to cash flow hedges, which includes foreign exchange contracts, foreign exchange options and interest rate swaps, are recorded in accumulated other comprehensive income and are recognized in the consolidated statement of operations when the hedged item affects earnings. Income Taxes The Company accounts for income taxes using an asset and liability approach for financial accounting and income tax reporting based on enacted tax rates. Deferred tax assets are reduced by a valuation allowance when it is more likely than not that some portion, or all, of the deferred tax assets will not be realized. Revenue Recognition The Company's revenues, which are composed of product, rental, service and other revenues, are generally subject to contractual arrangements which specify price and general terms and conditions. The Company recognizes product revenues, net of applicable provisions for returns, when title and the related risk of loss transfers to the customer. Rental, service and other revenues are recorded when such services are performed and collectibility is reasonably assured. Minority Interests The Company records minority interest expense which reflects the portion of the earnings of majority-owned operations which are applicable to the minority interest partners. The minority interest amount primarily represents the share of the M-I SWACO profits associated with the minority partner's 40 percent interest in those operations. To a lesser extent, minority interests include the portion of CE Franklin Ltd. and United Engineering Services LLC earnings applicable to the respective minority shareholders. Stock-Based Compensation Stock Options The Company's Board of Directors and its stockholders have authorized a long-term incentive plan, which includes stock options. As of December 31, 2004, 3.6 million shares were issued and outstanding under the stock option program and an additional 2.1 million shares were authorized for future issuance. Options are generally granted at the fair market value on the date of grant, vest over a four-year period and expire ten years after the date of grant. Approximately 0.1 million options awarded in 2001 were granted at a strike price more than five percent below the market value on the date of issuance and, thus, do not meet the conditions necessary to qualify as a non-compensatory option grant. Compensation expense related to these grants is being recognized over the four-year vesting period and resulted in the inclusion of $0.4 million, $0.4 million and $0.3 million of related expense in the accompanying consolidated statements of operations for the years ended December 31, 2004, 2003 and 2002, respectively. Until the required adoption of SFAS No. 123 (revised 2004), "Share-Based Payment" ("SFAS No. 123r") on July 1, 2005, the Company will continue to apply Accounting Principles Board Opinion No. 25, "Accounting for Stock Issued to Employees," and related interpretations in accounting for its stock option program as allowed under SFAS No. 123 "Accounting for Stock-Based Compensation." Therefore, for all options other than those mentioned above, the Company elects to make pro forma disclosures versus recognizing the related compensation expense in the accompanying consolidated financial statements. 35 Had the Company elected to apply the accounting standards of SFAS No. 123, the Company's net income and earnings per share would have approximated the pro forma amounts indicated below (in thousands, except per share data): 2004 2003 2002 -------- -------- ------- Net income, as reported ...................................... $182,451 $123,480 $93,189 Add: Stock-based compensation expense included in reported income, net of related tax effect ............. 273 273 182 Less: Total stock-based compensation expense determined under fair value methods, net of related tax effect .... (11,296) (10,838) (8,985) -------- -------- ------- Net income, pro forma ........................................ $171,428 $112,915 $84,386 ======== ======== ======= Earnings per share: As reported: Basic .................................................. $ 1.80 $ 1.24 $ 0.94 Diluted ................................................ 1.78 1.23 0.93 Pro forma: Basic .................................................. $ 1.69 $ 1.13 $ 0.85 Diluted ................................................ 1.67 1.12 0.84 Restricted Stock In addition to stock option awards, the Company's long-term incentive plan allows for the issuance of restricted stock and restricted stock units. In December 2004, the Board of Directors approved the grant of performance-based restricted stock units ("performance units"), subject to shareholder approval at the 2005 annual meeting. Compensation expense related to the restricted share awards, calculated as the difference between the market value on the date of grant and the exercise price, is recognized over the vesting period. The restricted stock units generally vest ratably over a four-year period. The performance units would vest over a three-year period and the number of shares awarded would be adjusted based upon the return on equity level attained by the Company during the fiscal year following the grant. The impact on compensation expense related to the restricted units granted in December 2004 is reflected in the above table; however, the performance units have been excluded as they have not been approved by the Company's stockholders. Recent Accounting Pronouncements In December 2004, the Financial Accounting Standards Board ("FASB") issued SFAS No. 123r, which replaces Statement No. 123 and supersedes Accounting Principles Board Opinion No. 25. SFAS No. 123r addresses the financial accounting and reporting of share-based payments to employees, including grants of stock options. SFAS No. 123r requires the recognition of compensation expense, which is measured based on the grant date fair value of equity awards, generally over the vesting period of the related stock option. The Company expects to adopt SFAS No. 123r effective July 1, 2005 and is evaluating the alternative transition methods allowed by the statement, including the modified prospective and limited modified retrospective methods. Under the modified prospective method, compensation cost related to all unvested stock options is recognized beginning with the effective date; however, the limited modified retrospective method permits restatement of prior periods assuming adoption of SFAS No 123r as of January 1, 2005. Although the Company continues to evaluate the standard and related transition matters, based on equity awards granted to employees through December 31, 2004 and those expected to be granted during the second quarter of 2005, share-based compensation expense on a full year basis is expected to total approximately $12.0 million, net of tax. From time to time, new accounting pronouncements are issued by the FASB which are adopted by the Company as of the specified effective date. Unless otherwise discussed, management believes the impact of recently issued standards, which are not yet effective, will not have a material impact on the Company's consolidated financial statements upon adoption. 36 2. LITIGATION-RELATED CHARGE During the second quarter of 2004, the Company recorded litigation-related charges totaling $31.4 million, or $20.4 million on an after-tax basis. The second quarter charge, which consists of an estimated loss provision, legal fees and other directly related costs, results from a complaint which alleged that certain of the Company's roller cone drill bit designs infringed several of the plaintiff's U.S. patents. Approximately $28.8 million of the charge is included in general and administrative expenses and the remainder is recorded in costs of revenues. Accrued liabilities associated with the litigation-related charge, which totaled $25.3 million as of December 31, 2004, are reflected in the accompanying consolidated balance sheet as other current liabilities. 3. CUMULATIVE EFFECT OF CHANGE IN ACCOUNTING On January 1, 2003, the Company adopted SFAS No. 143, "Accounting for Asset Retirement Obligations," which addresses the financial accounting and reporting for retirement obligations and costs associated with tangible long-lived assets. SFAS No. 143 requires that liabilities for asset retirement obligations be recognized during the periods incurred rather than when expended. The Company's asset retirement obligations principally relate to the removal of leasehold improvements upon exiting certain leased properties, primarily associated with the M-I SWACO operations. Upon adoption, the Company recognized a charge of $2.5 million, or $1.2 million after tax and minority interests, to reflect the cumulative amount of expense which was required to be recognized as of January 1, 2003. This amount has been recorded as a cumulative effect of change in accounting principle in the accompanying statement of operations. Additionally, the Company recorded a $3.7 million long-term liability at the adoption date reflecting the present value of projected future asset retirement obligations. The differential of $1.2 million, which primarily represents the associated capitalized retirement costs, will be charged to earnings over the remaining leasehold period. Neither the amounts charged to earnings in 2004 and 2003 nor the pro forma effect for the year ended December 31, 2002 (assuming adoption of SFAS No. 143 as of January 1, 2002) were significant to net income or earnings per share amounts. 4. BUSINESS COMBINATIONS AND ANNOUNCED TRANSACTIONS During 2004, the Company completed six acquisitions in exchange for aggregate cash consideration of $49.2 million and the assumption of certain liabilities. In addition, cash payments of $23.2 million were made during the year to former shareholders of businesses acquired in 2002 to fund amounts due under earn-out arrangements and repay seller-financed notes. The 2004 transactions primarily consist of the following: On January 31, 2004, M-I SWACO acquired certain specialty chemical assets of Fortum Oil and Gas OY for cash consideration of $11.4 million. The acquired operations, formerly based in Finland, manufacture and market specialty chemical products which improve hydrocarbon flow rates. On July 31, 2004, Smith Services acquired certain operating assets of CanFish Services for cash consideration of $17.5 million. The acquired operations provide fishing, milling, casing exit, pipe recovery and related wireline services in the United States and Canada. The excess of the purchase price over the estimated fair value of the net assets acquired amounted to $15.9 million and has been recorded as goodwill in the Oilfield Products and Services segment. Approximately one-half of the goodwill related to the 2004 acquisitions is expected to be deductible for tax purposes. The purchase price allocation related to certain of the 2004 acquisitions is based on preliminary information and is subject to change when additional data concerning final asset and liability valuations is obtained; however, material changes in the preliminary allocations are not anticipated by management. Additionally, in July 2004, the Company announced the signing of a non-binding letter of intent related to the sale of Wilson Industries, Inc. ("Wilson") to CE Franklin Ltd. Under the terms of the proposed transaction, CE Franklin would issue common stock and a note payable to the Company in exchange for the common stock of Wilson. Subsequent to the proposed transaction, the Company's ownership interest is expected to increase from the current 55 percent to a level in excess of 85 percent of the outstanding shares of CE Franklin. Accordingly, the Company would continue to consolidate the combined distribution operations of Wilson and CE Franklin. The transaction is subject to a number of factors, including negotiation of a definitive agreement, approval by the minority shareholders of CE Franklin, ratification by the Board of Directors of both companies and certain regulatory approvals. There are no assurances as to whether this transaction ultimately will be consummated. 37 During 2003, the Company completed three acquisitions in exchange for aggregate cash consideration of $92.1 million and the assumption of certain liabilities. In addition, cash payments of $9.7 million were made during the year to former shareholders of businesses acquired in 2002 to fund amounts due under earn-out arrangements and repay seller-financed notes. The 2003 transactions primarily consist of the following: On January 29, 2003, M-I SWACO acquired certain oilfield chemical assets of Dynea International in exchange for cash consideration of $77.8 million. The acquired operations, formerly based in Norway, provide a complete line of oilfield specialty chemicals used to eliminate hydrocarbon flow problems encountered during production and transportation. On October 1, 2003, M-I SWACO acquired certain operating assets of Alpine Mud Products for cash consideration of $14.1 million. The acquired operations market a line of specialty fluid additives used to enhance rates of penetration in critical drilling applications, primarily to customers in the U.S. Gulf Coast region. The excess of the purchase price over the estimated fair value of the net assets acquired amounted to $66.1 million, which has been recorded as goodwill predominantly in the Oilfield Products and Services segment. During 2002, the Company completed four acquisitions in exchange for aggregate cash consideration of $60.2 million, the issuance of $24.8 million of notes payable and the assumption of certain liabilities. The 2002 transactions primarily consist of the following: On July 31, 2002, the Company acquired certain turbodrilling assets of Neyrfor-Weir Ltd. in exchange for cash consideration of $25.3 million. The acquired operations, which design proprietary turbodrilling equipment and provide related services for horizontal and directional drilling applications, have been integrated into the Company's Oilfield Products and Services segment. On October 11, 2002, M-I SWACO acquired CleanCut Technologies ("CleanCut") for cash consideration of $16.1 million and the issuance of notes to sellers totaling $23.9 million. CleanCut, formerly based in Scotland, designs, manufactures and installs waste collection and transportation systems for offshore drilling operations. On November 28, 2002, M-I SWACO acquired IKF Services, a drilling fluids and solids-control company located in Russia, for cash consideration of $13.4 million. The excess of the purchase price over the estimated fair value of the net assets acquired amounted to $35.6 million in 2002, which has been recorded as goodwill in the Oilfield Products and Services segment. These acquisitions have been recorded using the purchase method of accounting and, accordingly, the acquired operations have been included in the results of operations since the date of acquisition. Pro forma results of operations have not been presented because the effect of these acquisitions was not material to the Company's consolidated financial statements. The following schedule summarizes investing activities related to 2004, 2003 and 2002 acquisitions included in the consolidated statements of cash flows: 2004 2003 2002 -------- -------- -------- Fair value of tangible and identifiable intangible assets, net of cash acquired .................................................... $ 44,103 $ 34,922 $ 57,480 Goodwill acquired ................................................... 15,860 66,147 35,616 Payments to former shareholders of businesses acquired .............. 23,162 9,692 -- Total liabilities assumed ........................................... (10,775) (8,972) (32,944) -------- -------- -------- Cash paid for acquisitions, net of cash acquired .................... $ 72,350 $101,789 $ 60,152 ======== ======== ======== 38 5. EARNINGS PER SHARE Basic earnings per share ("EPS") is computed using the weighted average number of common shares outstanding during the period. Diluted EPS gives effect to the potential dilution of earnings which could have occurred if additional shares were issued for stock option exercises under the treasury stock method. Outstanding employee stock options of 0.2 million, 1.1 million and 1.7 million as of December 31, 2004, 2003 and 2002, respectively, were not included in the computation of diluted earnings per common share as the exercise price was in excess of the average market price for the Company's stock during the corresponding period. The following schedule reconciles the income and shares used in the basic and diluted EPS computations (in thousands, except per share data): 2004 2003 2002 -------- -------- -------- BASIC EPS: Income before cumulative effect of change in accounting principle ......................... $182,451 $124,634 $ 93,189 ======== ======== ======== Weighted average number of common shares outstanding .................................. 101,332 99,815 98,984 ======== ======== ======== Basic EPS before cumulative effect of change in accounting principle ......................... $ 1.80 $ 1.25 $ 0.94 ======== ======== ======== DILUTED EPS: Income before cumulative effect of change in accounting principle ......................... $182,451 $124,634 $ 93,189 ======== ======== ======== Weighted average number of common shares outstanding .................................. 101,332 99,815 98,984 Dilutive effect of stock options ................ 1,237 1,088 1,107 -------- -------- -------- 102,569 100,903 100,091 ======== ======== ======== Diluted EPS before cumulative effect of change in accounting principle ...................... $ 1.78 $ 1.24 $ 0.93 ======== ======== ======== All 2002 weighted average share and option amounts have been restated for the impact of a two-for-one stock split effected in July 2002. 6. INVENTORIES Inventories consist of the following at December 31: 2004 2003 -------- -------- Raw materials ....................................................... $ 78,773 $ 62,631 Work-in-process ..................................................... 81,002 66,151 Products purchased for resale ....................................... 252,486 170,973 Finished goods ...................................................... 530,657 464,151 -------- -------- 942,918 763,906 Reserves to state certain U.S. inventories (FIFO cost of $337,080 and $266,328 in 2004 and 2003, respectively) on a LIFO basis ..... (52,456) (24,279) -------- -------- $890,462 $739,627 ======== ======== During 2004, the Company recorded additional LIFO reserves of $28.2 million, primarily reflecting higher commodity prices for steel and alloy products purchased by the Distribution segment. 39 7. PROPERTY, PLANT AND EQUIPMENT Property, plant and equipment consist of the following at December 31: 2004 2003 ---------- ---------- Land .............................. $ 35,954 $ 38,394 Buildings ......................... 147,442 134,568 Machinery and equipment ........... 555,469 511,615 Rental tools ...................... 376,043 323,977 ---------- ---------- 1,114,908 1,008,554 Less-Accumulated depreciation ..... (537,954) (473,683) ---------- ---------- $ 576,954 $ 534,871 ========== ========== 8. GOODWILL AND OTHER INTANGIBLE ASSETS Goodwill The following table presents goodwill on a segment basis as of the dates indicated, as well as changes in the account during the period shown. Beginning and ending goodwill balances are presented net of accumulated amortization of $53.6 million: Oilfield Distribution Segment Segment Consolidated -------- ------------ ------------ Balance as of December 31, 2002 .......... $582,786 $37,289 $620,075 Goodwill acquired ........................ 66,052 95 66,147 Purchase price and other adjustments ..... 3,984 387 4,371 -------- ------- -------- Balance as of December 31, 2003 .......... 652,822 37,771 690,593 Goodwill acquired ........................ 15,860 -- 15,860 Purchase price and other adjustments ..... 6,900 -- 6,900 -------- ------- -------- Balance as of December 31, 2004 .......... $675,582 $37,771 $713,353 ======== ======= ======== Other Intangible Assets The components of other intangible assets at December 31, are as follows: 2004 2003 --------------------------------- --------------------------------- Weighted Gross Gross Average Carrying Accumulated Carrying Accumulated Amortization Amount Amortization Net Amount Amortization Net Period -------- ------------ ------- -------- ------------ ------- ------------ (years) Patents ........................... $42,353 $14,532 $27,821 $38,520 $12,015 $26,505 15.6 License agreements ..................... 26,044 4,420 21,624 19,086 2,193 16,893 11.3 Non-compete agreements and trademarks ...... 20,772 8,899 11,873 19,583 5,649 13,934 12.5 Customer lists and contracts .................. 9,232 1,953 7,279 8,724 877 7,847 16.9 ------- ------- ------- ------- ------- ------- ---- $98,401 $29,804 $68,597 $85,913 $20,734 $65,179 13.9 ======= ======= ======= ======= ======= ======= ==== Amortization expense of other intangible assets was $9.1 million, $7.5 million and $3.4 million for the years ended December 31, 2004, 2003 and 2002, respectively. Additionally, estimated future amortization expense is expected to range between $5.1 million and $8.9 million a year for the next five fiscal years. 40 9. DEBT The following summarizes the Company's outstanding debt at December 31: 2004 2003 --------- -------- CURRENT: Short-term borrowings ................................................................... $ 107,204 $ 53,090 Current portion of long-term debt ....................................................... 104,171 36,657 --------- -------- Short-term borrowings and current portion of long-term debt .......................... $ 211,375 $ 89,747 ========= ======== LONG-TERM: Notes: 6.75% Senior Notes maturing February 2011 with an effective interest rate of 6.83% Interest payable semi-annually (presented net of unamortized discount of $605 and $723 in 2004 and 2003, respectively) ................................................. $ 219,395 $219,277 7.0% Senior Notes maturing September 2007 with an effective interest rate of 7.07% Interest payable semi-annually (presented net of unamortized discount of $277 and $381 in 2004 and 2003, respectively) ................................................. 149,723 149,619 7.7% Senior Secured Notes maturing July 2007. Principal due in equal annual installments of $7.1 million. Interest payable semi-annually ......................... 21,428 28,571 7.63% Notes payable to insurance companies maturing April 2006. Principal due in equal annual installments of $3.3 million. Interest payable semi-annually ........... 6,667 10,000 Notes payable to various individuals repaid September 2004 .............................. -- 16,262 Bank revolvers payable: $250.0 million revolving note expiring July 2005. Interest payable quarterly at base rate (5.25% at December 31, 2004) or Eurodollar rate, as defined (3.10% at December 31, 2004) and described below ..................................... 80,000 66,000 M-I SWACO $150.0 million revolving note expiring July 2005. Interest payable quarterly at base rate (5.25% at December 31, 2004) or Eurodollar rate, as defined (3.10% at December 31, 2004) and described below ..................................... -- -- Term Loans: M-I SWACO 315.0 million Norwegian Krone term loan payable to a financial institution. Principal due in semi-annual installments of 45.0 million Krone through June 2006. Interest payable semi-annually at adjusted Norwegian Interbank Offered Rate (3.01% at December 31, 2004) ......................................................... 10,689 31,118 Other ................................................................................... 4,067 4,358 --------- -------- 491,969 525,205 Less-Current portion of long-term debt .................................................. (104,171) (36,657) --------- -------- Long-term debt ....................................................................... $ 387,798 $488,548 ========= ======== Principal payments of long-term debt for years subsequent to 2005 are as follows: 2006 ......... $ 10,885 2007 ......... 156,983 2008 ......... 21 2009 ......... -- Thereafter ... 219,909 -------- $387,798 ======== 41 The Company's short-term borrowings consist of amounts outstanding under lines of credit and short-term loans. Certain subsidiaries of the Company have unsecured credit facilities with non-U.S. banks aggregating $163.5 million with $56.3 million of additional borrowing capacity available under these facilities at December 31, 2004. These borrowings had a weighted average interest rate of 7.5 percent and 8.3 percent at December 31, 2004 and 2003, respectively. In addition to the credit facilities discussed above, the Company has an unsecured revolving credit facility provided by a syndicate of nine financial institutions. The revolving credit agreement (the "Agreement"), which expires July 2005, includes a $400.0 million committed line of credit with a $50.0 million letter of credit sub-facility. The Agreement allows for the election of interest at a base rate, or a Eurodollar rate ranging from LIBOR plus 62.5 to 75.0 basis points depending on amounts drawn under the facility. The Agreement also requires the payment of a quarterly commitment fee of 15 basis points on the unutilized portion of the facility and compliance with certain customary covenants, including maintenance of specified debt-to-total capitalization and interest coverage ratios, as defined. The LIBOR interest margins and the commitment fee are subject to adjustment depending on the senior debt rating of the Company. As of December 31, 2004, the Company had $80.0 million drawn and $4.5 million of letters of credit issued under the facility, resulting in additional borrowing capacity of $315.5 million. The 6.75 percent and 7.0 percent Senior Notes are unsecured obligations of the Company issued under an Indenture dated September 8, 1997. The Indenture contains no financial covenants, nor any restrictions related to the payment of cash dividends to common stockholders. The Company's 6.75 percent and 7.0 percent Senior Notes are redeemable by the Company, in whole or in part, at any time prior to maturity at a redemption price equal to accrued interest plus the greater of the principal amount or the present value of the remaining principal and interest payments. The Company was in compliance with its loan covenants under the various loan indentures, as amended, at December 31, 2004. 10. FINANCIAL INSTRUMENTS Foreign Currency Contracts The Company enters into spot and forward contracts as a hedge against foreign currency denominated assets and liabilities and foreign currency commitments. The term of these contracts generally do not exceed two years. For fair value hedges, realized and unrealized gains and losses are recognized currently through earnings, and the resulting amounts generally offset foreign exchange gains or losses on the related accounts. The Company recognized expense of approximately $2.4 million, $4.9 million and $1.1 million in 2004, 2003 and 2002, respectively, related to net realized and unrealized losses on fair value hedge contracts. Gains or losses on designated cash flow hedge contracts are deferred to accumulated other comprehensive income and recognized in the consolidated statement of operations when the hedged item affects earnings. The Company recognized earnings of approximately $4.2 million, $4.4 million and $0.6 million in 2004, 2003 and 2002, respectively, related to cash flow hedge contracts. As of December 31, 2004, the notional amount of fair value hedge contracts outstanding was $97.2 million, approximating the fair value of these contracts, and there were no cash flow hedge contracts outstanding. As of December 31, 2003, the notional amounts of fair value hedge contracts and cash flow hedge contracts outstanding were $45.5 million and $9.2 million, respectively, and the fair value exceeded the notional amount of these contracts by $1.9 million. Fair Value of Other Financial Instruments The recorded and fair values of long-term debt at December 31 are as follows: 2004 2003 -------------------- ------------------- Recorded Fair Recorded Fair Value Value Value Value --------- -------- -------- -------- Long-term Debt... $491,969 $531,302 $525,205 $576,917 The fair value of long-term debt was primarily determined using quoted market prices. The fair value of the remaining financial instruments, including cash and cash equivalents, receivables, payables and short-term borrowings, approximates the carrying value due to the short-term nature of these instruments. 42 11. INCOME TAXES The geographical sources of income before income taxes, minority interests and cumulative effect of change in accounting principle for the three years ended December 31, 2004 were as follows: 2004 2003 2002 -------- -------- -------- Income before income taxes, minority interests and cumulative effect of change in accounting principle: United States ......................................... $119,770 $ 62,984 $ 40,198 Non-United States ..................................... 281,532 226,772 177,601 -------- -------- -------- Total ................................................. $401,302 $289,756 $217,799 ======== ======== ======== The income tax provision is summarized as follows: 2004 2003 2002 -------- ------- ------- Current: United States ....... $ 47,651 $22,604 $(3,027) Non-United States ... 82,781 61,440 44,260 State ............... 1,053 1,136 1,839 -------- ------- ------- 131,485 85,180 43,072 -------- ------- ------- Deferred: United States ....... (2,116) 756 18,738 Non-United States ... 925 7,398 4,822 State ............... (573) -- -- -------- ------- ------- (1,764) 8,154 23,560 -------- ------- ------- Income tax provision ... $129,721 $93,334 $66,632 ======== ======= ======= The consolidated effective tax rate (as a percentage of income before income taxes, minority interests and cumulative effect of change in accounting principle) is reconciled to the U.S. federal statutory tax rate as follows: 2004 2003 2002 ---- ---- ---- U.S. federal statutory tax rate ............................ 35.0% 35.0% 35.0% Minority partners' share of U.S. partnership earnings ...... (2.9) (3.1) (3.6) Non-deductible expenses .................................... 1.0 1.1 0.7 Benefit of foreign sales corporation and extraterritorial income exclusion ........................................ (0.7) (0.7) (0.7) State taxes, net ........................................... 0.1 0.6 0.8 Non-U.S. tax provisions which vary from the U.S. rate/non-U.S. losses with no tax benefit realized ....... (0.6) 0.8 (1.2) Change in valuation allowance .............................. (0.2) (1.3) -- Other items, net ........................................... 0.6 (0.2) (0.5) ---- ---- ---- Effective tax rate ......................................... 32.3% 32.2% 30.5% ==== ==== ==== 43 The components of deferred taxes at December 31 are as follows: 2004 2003 --------- --------- Deferred tax liabilities attributed to the excess of net book basis over remaining tax basis (principally depreciation): United States ................................................ $ (73,118) $ (60,795) Non-United States ............................................ (49,795) (46,517) --------- --------- Total deferred tax liabilities ............................... (122,913) (107,312) --------- --------- Deferred tax assets attributed to net operating loss and tax credit carryforwards: United States ................................................ 1,110 -- Non-United States ............................................ 15,317 16,039 Other deferred tax assets (principally accrued liabilities not deductible until paid and inventories): United States ................................................ 61,157 49,400 Non-United States ............................................ 7,872 6,243 --------- --------- Subtotal ..................................................... 85,456 71,682 Valuation allowance ............................................. (15,068) (15,283) --------- --------- Total deferred tax assets ....................................... 70,388 56,399 --------- --------- Net deferred tax liabilities ................................. $ (52,525) $ (50,913) ========= ========= Balance sheet presentation: Deferred tax assets, net ..................................... $ 47,083 $ 31,238 Other assets ................................................. 3,459 4,140 Income taxes payable ......................................... (9,290) (6,226) Deferred tax liabilities ..................................... (93,777) (80,065) --------- --------- Net deferred tax liabilities ................................. $ (52,525) $ (50,913) ========= ========= At December 31, 2004, the accompanying consolidated financial statements include $15.3 million of deferred tax assets associated with operating loss carryforwards in tax jurisdictions outside the United States. Although the majority of these losses will carryforward indefinitely and are available to reduce future tax liabilities of the respective foreign entity, we do not currently believe the majority of these assets will be realized and have, accordingly, established a $15.1 million valuation reserve. The valuation allowance as of December 31, 2003 totaled $15.3 million which consisted of established reserves for foreign operating loss carryforwards. During 2004, the valuation allowance was reduced by $0.2 million as a result of expiration of operating loss carryforwards and changes in the anticipated realizability of certain foreign deferred tax assets. The Company has provided additional taxes for the anticipated repatriation of certain earnings of its non-U.S. subsidiaries. Undistributed earnings above the amounts upon which additional taxes have been provided, which approximated $228.4 million at December 31, 2004, are intended to be permanently invested by the Company. It is not practicable to determine the amount of applicable taxes that would be incurred if any of such earnings were repatriated. The American Jobs Creation Act of 2004 (the "Act"), which was enacted during the fourth quarter of 2004, creates a temporary incentive for U.S. corporations to repatriate accumulated earnings of non-U.S. subsidiaries by providing an 85 percent deduction for certain dividends from controlled foreign corporations. While the Company continues to evaluate the provisions of the new tax law and potential repatriations, management estimates that approximately $436.0 million of accumulated earnings generated in jurisdictions outside of the United States currently remain undistributed. Since the Company has not completed its evaluation and, as of the current date, final guidance has not been issued, management cannot reasonably estimate the amount, it any, of repatriations which would be subject to the temporary tax relief. In accordance with FASB Staff Position No. 109-2, "Accounting and Disclosure Guidance for the Foreign Earnings Repatriation Provision within the American Jobs Creation Act of 2004," the tax deduction, if any, will be recorded in the period in which the effect becomes estimable. 44 12. STOCKHOLDERS' EQUITY Dividend Program Subsequent to December 31, 2004, the Company's Board of Directors approved a cash dividend program for stockholders and declared a quarterly cash dividend of $0.12 per share, with the first dividend payment to be made April 15, 2005 to stockholders of record on March 15, 2005. The level of future dividend payments will be at the discretion of the Board of Directors and will depend upon the Company's financial condition, earnings and cash flow from operations, the level of its capital expenditures, compliance with certain debt covenants, its future business prospects and other factors that the Board of Directors deems relevant. Common Stock Repurchases During 2001, the Company's Board of Directors authorized a share buyback program which allows for the repurchase of up to 5.0 million shares of common stock, subject to regulatory issues, market considerations and other relevant factors. During 2004, the Company repurchased 1.8 million shares of common stock at an aggregate cost of $92.0 million, bringing the total number of shares acquired under the program to 2.9 million. The acquired shares have been added to the Company's treasury stock holdings and may be used in the future for acquisitions or other corporate purposes. Future repurchases under the program may be executed from time to time in the open market or in privately negotiated transactions. Stock Split On June 6, 2002, the Company's Board of Directors approved a two-for-one stock split, effected in the form of a stock dividend. Stockholders of record as of June 20, 2002 were entitled to the dividend, which was distributed on July 8, 2002. Unless otherwise noted, all share and option amounts included in the accompanying consolidated financial statements and related notes reflect the effect of the stock split. Stockholder Rights Plan On June 8, 2000, the Company adopted a Stockholder Rights Plan (the "Rights Plan") to replace a similar plan which expired on June 19, 2000. As part of the Rights Plan, the Company's Board of Directors declared a dividend of one preferred stock purchase right ("Right") for each share of the Company's common stock outstanding on June 20, 2000. The Board also authorized the issuance of one such Right for each share of the Company's common stock issued after June 20, 2000 until the occurrence of certain events. The Rights are exercisable upon the occurrence of certain events related to a person (an "Acquiring Person") acquiring or announcing the intention to acquire beneficial ownership of 20 percent or more of the Company's common stock. When the rights become exercisable, each holder (except an Acquiring Person) will be entitled to purchase, at an effective exercise price of $175, shares of the Company's common stock having a market value of twice the Right's exercise price, subject to adjustment. The Acquiring Person will not be entitled to exercise these Rights. In addition, if the Company is involved in a merger or other business combination transaction, or sells 50 percent or more of its assets or earning power to another entity, each Right will entitle its holder to purchase, at the Right's then current exercise price, shares of common stock of such other entity having a value of twice the Right's exercise price. The Rights are subject to redemption at the option of the Board of Directors at a price of one-half of a cent per Right until the occurrence of certain events. The Rights currently trade with the Company's common stock, have no voting or dividend rights and expire on June 8, 2010. Accumulated Other Comprehensive Income Accumulated other comprehensive income in the accompanying consolidated balance sheets consists of the following: 2004 2003 ------- ------- Currency translation adjustments......... $27,783 $12,820 Unrealized fair value of derivatives..... (132) 2,339 Pension liability adjustments............ (3,247) (3,534) ------- ------- Accumulated other comprehensive income... $24,404 $11,625 ======= ======= Approximately $0.2 million of the unrealized fair value of derivatives is expected to be recognized as after-tax earnings during the fiscal year ending December 31, 2005. 45 13. RETIREMENT PLANS Defined Contribution Plans The Company established the Smith International, Inc. 401(k) Retirement Plan (the "Smith Plan") for the benefit of all eligible employees. Employees may voluntarily contribute a percentage of their compensation, as defined, to the Smith Plan. The Company makes basic, retirement and, in certain cases, discretionary matching contributions to each participant's account under the Smith Plan. Participants receive a basic match on contributions to the Smith Plan of up to 1 1/2 percent of qualified compensation and a retirement contribution ranging from two percent to six percent of qualified compensation. In addition, the Board of Directors may provide discretionary profit-sharing contributions based upon financial performance to participants who are employed by the Company on December 31. Through September 30, 2004, eligible employees of Wilson Industries, Inc. (the "Wilson employees") participated in the Smith Plan. Effective October 1, 2004, the Company established the Wilson 401(k) Retirement Plan (the "Wilson Plan") and transferred account balances of the Wilson employees into this plan from the Smith Plan. Employees may voluntarily contribute a percentage of their compensation, as defined, to the Wilson Plan. Wilson makes matching contributions to each participant's account ranging from two to six percent of qualified compensation. In addition, the Board of Directors may provide discretionary profit-sharing contributions based upon financial performance to participants who are employed by Wilson on December 31. M-I SWACO has a company Profit-Sharing and Savings Plan (the "M-I Retirement Plan") under which participating employees may voluntarily contribute a percentage of their compensation, as defined. At its discretion, M-I SWACO may make basic, matching and in certain cases, discretionary matching contributions to each participant's account under the M-I Retirement Plan. Participants are eligible to receive a basic contribution equal to three percent of qualified compensation, and a full match on employee contributions of up to 1 1/2 percent of qualified compensation. In addition, the Board of Directors may provide discretionary profit-sharing contributions based upon financial performance to participants who are employed by M-I SWACO on December 31. The Company recognized expense totaling $34.0 million, $25.0 million and $17.6 million in 2004, 2003 and 2002, respectively, related to Company contributions to the plans. Certain of the Company's subsidiaries sponsor various defined contribution plans. The Company's contributions under these plans for each of the three years in the period ended December 31, 2004, were immaterial. Deferred Compensation Plan The Company maintains a Supplemental Executive Retirement Plan ("SERP"), a non-qualified, deferred compensation program, for the benefit of officers and certain other eligible employees of the Company. Participants may contribute, on a pre-tax basis, maximum amounts ranging from 50 percent to 100 percent of cash compensation, as defined. Plan provisions allow for retirement and matching contributions, similar to those provided under the Company's defined contribution programs, and, in certain cases, an interest contribution in order to provide a yield on short-term investments equal to 120 percent of the long-term applicable federal rate, as defined. In the event of insolvency or bankruptcy, plan assets are available to satisfy the claims of all general creditors of the Company. Accordingly, the accompanying consolidated balance sheets reflect the aggregate participant balances as both an asset and a liability of the Company. As of December 31, 2004 and 2003, $42.0 million and $35.8 million, respectively, are included in other assets with a corresponding amount recorded in other long-term liabilities. During the years ended December 31, 2004, 2003 and 2002, Company contributions to the plan totaled $2.6 million, $2.4 million and $1.9 million, respectively. 46 14. EMPLOYEE BENEFIT PLANS The Company currently maintains various defined benefit pension plans covering certain U.S. and non-U.S. employees. Future benefit accruals and the addition of new participants under the U.S. plans were frozen prior to 1998. Participation in certain non-U.S. pension plans has recently increased due to continued business expansion, in part associated with acquired operations; and accordingly, the prior years' information has been conformed to the 2004 presentation, where applicable. The Company and certain subsidiaries have postretirement benefit plans which provide health care benefits to a limited number of current, and in certain cases, future retirees. Individuals who elect to contribute premiums are eligible to participate in the Company's medical and prescription drug programs, with certain limitations. In addition to premiums, the retiree is responsible for deductibles and any required co-payments and is subject to annual and lifetime dollar spending caps. The following tables disclose the changes in benefit obligations and plan assets during the periods presented and reconcile the funded status of the plans to the amounts included in the accompanying consolidated balance sheets: PENSION PLANS POSTRETIREMENT BENEFIT PLANS ----------------- ---------------------------- 2004 2003 2004 2003 ------- ------- -------- -------- Changes in benefit obligations: Benefit obligations at beginning of year ......... $35,701 $31,072 $ 11,160 $ 10,581 Service cost ..................................... 2,355 1,889 233 219 Interest cost .................................... 2,181 1,934 643 685 Plan participants' contributions ................. 54 41 790 735 Actuarial loss (gain) ............................ 2,394 1,778 (929) 783 Benefits paid .................................... (1,116) (1,013) (1,155) (1,843) ------- ------- -------- -------- Benefit obligations at end of year ............... $41,569 $35,701 $ 10,742 $ 11,160 ======= ======= ======== ======== Changes in plan assets: Fair value of plan assets at beginning of year ... $28,771 $24,719 $ -- $ -- Actual return on plan assets ..................... 3,686 2,848 -- -- Employer contributions ........................... 3,537 2,176 365 1,108 Plan participants' contributions ................. 54 41 790 735 Benefits paid .................................... (1,116) (1,013) (1,155) (1,843) ------- ------- -------- -------- Fair value of plan assets at end of year ......... $34,932 $28,771 $ -- $ -- ======= ======= ======== ======== Funded status .................................... $(6,637) $(6,930) $(10,742) $(11,160) Unrecognized net actuarial loss (gain) ........... 7,028 6,775 (4,148) (3,391) Unrecognized prior service cost .................. (77) (73) (1,551) (1,916) Unrecognized net transition obligation (asset) ... 44 (437) -- -- ------- ------- -------- -------- Net prepaid benefit (accrued liability) .......... $ 358 $ (665) $(16,441) $(16,467) ======= ======= ======== ======== The net prepaid benefit (liability) associated with the Pension Plans is reflected in the accompanying consolidated balance sheets in the following captions: Prepaid expenses and other............... $ 2,221 $ 1,453 Other long-term liabilities.............. (6,286) (7,289) Deferred taxes........................... 1,176 1,637 Accumulated other comprehensive income... 3,247 3,534 ------- ------- Net amount recognized.................... $ 358 $ (665) ======= ======= Accrued liabilities associated with the Postretirement Benefit Plans, which totaled $16.4 million and $16.5 million as of December 31, 2004 and 2003, respectively, are reflected in the accompanying consolidated balance sheets as other long-term liabilities. 47 Net Periodic Benefit Expense Net periodic benefit expense and the weighted average assumptions used to determine the net benefit expense for the fiscal years ended December 31 and the projected benefit obligation at December 31 are as follows: PENSION PLANS POSTRETIREMENT BENEFIT PLANS --------------------------- ---------------------------- 2004 2003 2002 2004 2003 2002 ------- ------- ------- ----- ----- ----- Components of net periodic benefit expense: Service cost............................... $ 2,355 $ 1,889 $ 1,403 $ 233 $ 219 $ 220 Interest cost.............................. 2,181 1,934 1,833 643 685 981 Return on plan assets...................... (2,050) (1,701) (1,668) -- -- -- Amortization of prior service cost......... 82 118 68 (365) (365) (243) Amortization of loss (gain)................ 355 275 107 (172) (251) (243) ------- ------- ------- ----- ----- ----- Net periodic benefit expense............... $ 2,923 $ 2,515 $ 1,743 $ 339 $ 288 $ 715 ======= ======= ======= ===== ===== ===== Net periodic benefit expense: Discount rate.............................. 6.00% 6.75% 7.25% 6.00% 6.75% 7.25% Expected return on plan assets............. 8.50% 8.50% 8.50% N/A N/A N/A Projected benefit obligation: Discount rate.............................. 5.75% 6.00% 6.75% 5.75% 6.00% 6.75% Expected return on plan assets............. 8.50% 8.50% 8.50% N/A N/A N/A Additional Pension Plan Information In determining the expected return on plan assets, the Company considers the investment mix, the historical market performance and economic and other indicators of future performance. The Company primarily utilizes a mix of common stock and fixed income index funds to generate asset returns comparable with the general market. The investment mix of pension assets at December 31 is summarized in the following table: 2004 2003 ---- ---- Common stock and related index funds.............. 43% 44% Fixed income securities and related index funds... 33 32 Real estate....................................... 4 3 Money market funds................................ 20 21 ---- ---- Total.......................................... 100% 100% ==== ==== For pension plans with accumulated benefit obligations in excess of plan assets, the following table sets forth the projected and accumulated benefit obligations and the fair value of plan assets at December 31: 2004 2003 ------- ------- Projected benefit obligation..... $41,569 $35,701 Accumulated benefit obligation... 41,569 35,701 Plan assets at fair value........ 34,932 28,771 Estimated future benefit payments based on projected future service are expected to range between $0.6 million and $1.0 million a year for the next five years and approximate $6.8 million for the five-year period ending December 31, 2014. Company contributions to the pension plans during 2005 are expected to be comparable to the $3.5 million contributed in 2004. 48 Additional Postretirement Benefit Plan Information The assumed health care cost trend rates used to determine the projected postretirement benefit obligation at December 31 are as follows: 2004 2003 ---- ----- Health care cost trend rate for current year............................. 10% 10% Rate that the cost trend rate gradually declines (ultimate trend rate)... 5% 5% Year that the rate reaches the ultimate trend rate....................... 2009 2008 A one-percentage point change in assumed health care cost trend rates would have the following effects on the benefit obligations and the aggregate of the service and interest cost components of the postretirement benefits expense: ONE- ONE- PERCENTAGE- PERCENTAGE- POINT POINT INCREASE DECREASE ----------- ----------- Effect on total service and interest cost................. $ 84 $ (85) Effect on accumulated postretirement benefit obligation... 468 (696) Estimated future benefit payments based on projected future service are expected to range between $0.7 million and $0.9 million a year for the next five years and approximate $5.1 million for the five-year period ending December 31, 2014. Company contributions to the postretirement benefit plans during 2005 are expected to be comparable to the $0.4 million contributed in 2004. 15. LONG-TERM INCENTIVE COMPENSATION The Company maintains a long-term incentive compensation program, including stock options and restricted stock awards, for the benefit of key employees. Stock Options A summary of the Company's stock option program is presented below. SHARES WEIGHTED AVERAGE UNDER OPTION EXERCISE PRICE ------------ ---------------- Outstanding at December 31, 2001... 5,168,798 $22.21 Options granted.................... 1,399,180 33.66 Options forfeited.................. (116,722) 24.43 Options exercised.................. (223,492) 13.93 ----------- ------ Outstanding at December 31, 2002... 6,227,764 25.04 Options granted.................... 1,047,000 38.82 Options forfeited.................. (38,196) 29.77 Options exercised.................. (1,161,564) 19.02 ----------- ------ Outstanding at December 31, 2003... 6,075,004 28.53 Options granted.................... 191,456 56.26 Options forfeited.................. (79,841) 34.67 Options exercised.................. (2,555,579) 22.83 ----------- ------ Outstanding at December 31, 2004... 3,631,040 $33.88 =========== ====== 49 The number of outstanding fixed stock options exercisable at December 31, 2003 and 2002 was 3,261,816 and 3,205,106, respectively. These options had a weighted average exercise price of $24.30 and $21.21 at December 31, 2003 and 2002, respectively. The following summarizes information about fixed stock options outstanding at December 31, 2004: Options Outstanding Options Exercisable ----------------------------------------- ---------------------- Weighted Weighted Weighted Average Average Average Range of Number Remaining Exercise Number Exercise Exercise Prices Outstanding Contractual Life Price Exercisable Price --------------- ----------- ---------------- -------- ----------- -------- $ 8.94 - $11.78 15,937 3.7 $11.60 15,937 $11.60 $19.60 - $23.50 822,930 6.7 23.08 639,685 22.95 $30.75 - $36.52 1,587,037 7.1 33.77 1,036,648 33.27 $38.82 - $56.26 1,205,136 9.1 41.68 251,545 38.82 --------- --- ------ --------- ------ 3,631,040 7.7 $33.88 1,943,815 $30.41 ========= === ====== ========= ====== The pro forma net income and earnings per share data disclosed in Note 1 has been determined as if the Company had accounted for its employee stock-based compensation program under the fair value method of SFAS No. 123. The Company used an open form (lattice) model to determine the fair value of each 2004 option grant, and accordingly, calculate the stock-based compensation expense. The Black-Scholes method was used to calculate the fair value of options granted prior to 2004. The fair value and assumptions used are as follows: 2004 2003 2002 ------ ------ ------ Fair value of stock options granted ... $17.84 $13.02 $15.36 Expected life of option (years) ....... 5.0 5.0 5.0 Expected stock volatility ............. 31.0% 31.0% 46.3% Expected dividend yield ............... N/A N/A N/A Risk-free interest rate ............... 3.6% 3.5% 3.2% Restricted Stock In addition to stock option awards, the Company's long-term incentive plan allows for the issuance of restricted stock and restricted stock units. In December 2004, the Board of Directors approved the grant of performance-based restricted stock units ("performance units"), subject to shareholder approval at the 2005 annual meeting. Restricted stock units representing 40,504 shares were issued in December 2004 with a grant date market value of $56.26 per share. Accordingly, compensation expense related to the restricted unit awards, calculated as the difference between the market value and the exercise price, is recognized ratably over the four-year vesting period and totaled approximately $0.1 million in 2004. If approved at the 2005 annual meeting, approximately 153,340 performance units will be awarded during the second quarter of 2005. The number of units ultimately issued, however, will be subject to adjustment based on the return on equity attained by the Company. Compensation expense for the performance units will be recognized ratably over the three-year vesting period and, if necessary, periodic adjustments will be recorded to account for changes in expected return on equity. Although there is no assurance that the proposal will be approved at the 2005 annual meeting, if the performance units had been issued on December 31, 2004, the related annual compensation expense would have approximated $3.0 million. 16. INDUSTRY SEGMENTS AND INTERNATIONAL OPERATIONS The Company manufactures and markets premium products and services to the oil and gas exploration and production industry, the petrochemical industry and other industrial markets. The Company aggregates its operations into two reportable segments: Oilfield Products and Services and Distribution. The Oilfield Products and Services segment consists of three business units: M-I SWACO, which provides drilling and completion fluid systems and services, solids-control and separation equipment, waste-management services and oilfield production chemicals; Smith Technologies, which designs, manufactures and sells three-cone drill bits, diamond drill bits and turbine products; and Smith Services, which manufactures and markets products and services used for drilling, workover, well completion and well re-entry operations. The principal markets for the Oilfield segment include all major oil and gas-producing regions of the world, with approximately 60 percent of revenues generated in markets outside of North America. Oilfield segment customers primarily include major multi-national, independent and national, or state-owned, oil companies. 50 The Distribution segment consists of one business unit, Wilson, which markets pipe, valves, fittings and mill, safety and other maintenance products to energy and industrial markets. The Distribution segment has the most significant North American exposure of any of the Company's operations with approximately 90 percent of revenues derived in the United States and Canada. Approximately two-thirds of Wilson's revenues are generated from customers in the energy sector, which includes major multi-national and independent oil companies, pipeline companies and contract drilling companies. The remainder relates to sales in the downstream and industrial markets, which primarily includes refineries, petrochemical and power generation plants. The Company's revenues are derived principally from uncollateralized customer sales. The significant energy industry concentration has the potential to impact the Company's exposure to credit risk, either positively or negatively, because customers may be similarly affected by changes in economic or other conditions. The creditworthiness of the Company's customer base is strong, with limited credit losses experienced on such receivables. The following table presents financial information for each reportable segment: 2004 2003 2002 ---------- ---------- ---------- Revenues: Oilfield Products and Services ... $3,236,339 $2,678,274 $2,282,909 Distribution ..................... 1,182,676 916,554 887,171 ---------- ---------- ---------- $4,419,015 $3,594,828 $3,170,080 ========== ========== ========== Operating Income (Loss): Oilfield Products and Services ... $ 423,648 $ 343,486 $ 266,692 Distribution ..................... 26,513 (7,897) (4,026) General corporate ................ (11,397) (6,842) (6,518) ---------- ---------- ---------- $ 438,764 $ 328,747 $ 256,148 ========== ========== ========== Capital Expenditures: Oilfield Products and Services ... $ 108,773 $ 96,458 $ 91,056 Distribution ..................... 2,428 2,009 3,401 General corporate ................ 248 456 2,594 ---------- ---------- ---------- $ 111,449 $ 98,923 $ 97,051 ========== ========== ========== Depreciation and Amortization: Oilfield Products and Services ... $ 98,258 $ 93,541 $ 81,924 Distribution ..................... 7,209 6,913 5,857 General corporate ................ 1,026 1,255 1,546 ---------- ---------- ---------- $ 106,493 $ 101,709 $ 89,327 ========== ========== ========== Total Assets: Oilfield Products and Services ... $2,905,850 $2,604,176 $2,301,735 Distribution ..................... 493,434 405,413 368,206 General corporate ................ 107,494 87,458 79,604 ---------- ---------- ---------- $3,506,778 $3,097,047 $2,749,545 ========== ========== ========== The following table presents consolidated revenues by region: 2004 2003 2002 ---------- ---------- ---------- United States .......... $1,982,467 $1,592,243 $1,492,710 Canada ................. 487,552 362,874 286,640 ---------- ---------- ---------- North America ....... 2,470,019 1,955,117 1,779,350 ---------- ---------- ---------- Latin America .......... 424,053 344,283 305,498 Europe/Africa .......... 961,755 855,916 681,947 Middle East ............ 366,114 302,872 276,365 Far East ............... 197,074 136,640 126,920 ---------- ---------- ---------- Non-North America ... 1,948,996 1,639,711 1,390,730 ---------- ---------- ---------- $4,419,015 $3,594,828 $3,170,080 ========== ========== ========== 51 The following table presents net property, plant and equipment by region: 2004 2003 2002 -------- -------- -------- United States .......... $306,505 $295,243 $299,206 Canada ................. 34,603 29,918 27,854 -------- -------- -------- North America ....... 341,108 325,161 327,060 -------- -------- -------- Latin America .......... 50,208 51,831 49,469 Europe/Africa .......... 133,290 107,347 102,188 Middle East ............ 32,920 32,364 24,988 Far East ............... 19,428 18,168 15,515 -------- -------- -------- Non-North America ... 235,846 209,710 192,160 -------- -------- -------- $576,954 $534,871 $519,220 ======== ======== ======== The Company's expenditures for research and engineering activities are attributable to the Company's Oilfield Products and Services segment and totaled $67.2 million in 2004, $55.6 million in 2003 and $50.6 million in 2002. 17. COMMITMENTS AND CONTINGENCIES Leases The Company routinely enters into operating and capital leases for certain of its facilities and equipment. Amounts related to assets under capital lease were immaterial for the periods presented. Rent expense totaled $94.8 million, $79.0 million and $71.2 million in 2004, 2003 and 2002, respectively. Future minimum payments under non-cancelable operating leases having initial terms of one year or more are as follows: AMOUNT -------- 2005 ......... $ 43,263 2006 ......... 33,120 2007 ......... 23,914 2008 ......... 16,920 2009 ......... 11,771 2010-2014 .... 29,541 Thereafter ... 17,654 -------- $176,183 ======== In the normal course of business, the Company enters into lease agreements with cancellation provisions as well as agreements with initial terms of less than one year. The costs related to these leases have been reflected in rent expense but have been appropriately excluded from the future minimum payments presented above. Standby Letters of Credit and Guarantees In the normal course of business with customers, vendors and others, the Company is contingently liable for performance under standby letters of credit and bid, performance and surety bonds. Certain of these outstanding instruments guarantee payment to insurance companies which reinsure certain liability coverages of the Company's insurance captive. Excluding the impact of these instruments, for which $15.5 million of related liabilities are reflected in the accompanying consolidated balance sheet, the Company is contingently liable for approximately $65.4 million of standby letters of credit and bid, performance and surety bonds at December 31, 2004. Management does not expect any material amounts to be drawn on these instruments. During the fourth quarter of 2004, the Company obtained a surety bond in the amount of $43.5 million in connection with its appeal of the patent infringement litigation discussed below. After taking into consideration amounts reflected in the accompanying consolidated balance sheet, the Company has a contingent liability of up to $18.2 million associated with this instrument. Management, however, does not expect any amounts to be drawn on this instrument. 52 The Company has also provided loan guarantees related to certain joint ventures accounted for under the equity method of accounting. As the net assets and cash flows of these entities are available to satisfy obligations as they become due, management believes the likelihood is remote that the Company will be required to perform under these guarantees. The Company's estimated maximum exposure under these loan guarantees approximated $20.8 million as of December 31, 2004. Insurance The Company maintains insurance coverage for various aspects of its business and operations. The Company has elected to retain a portion of losses that occur through the use of deductibles and retentions under its insurance programs. Amounts in excess of the self-insured retention levels are fully insured to limits believed appropriate for the Company's operations. Self-insurance accruals are based on claims filed and an estimate for claims incurred but not reported. While management believes that amounts accrued in the accompanying consolidated financial statements are adequate for expected liabilities arising from the Company's portion of losses, estimates of these liabilities may change as circumstances develop. Litigation Halliburton Energy Services, Inc. v. Smith International, Inc. In September 2002, the Company was served with a complaint in the U.S. District Court for the Eastern District of Texas, Sherman Division entitled Halliburton Energy Services, Inc. v. Smith International, Inc. This lawsuit is a patent infringement claim alleging that certain roller cone drill bits made by the Company infringe several U.S. patents owned by Halliburton. The case was tried in the second quarter of 2004 and ultimately the plaintiff was awarded $41.1 million, which includes the original jury assessment of $24.0 million, a subsequent award enhancement, attorney's fees and prejudgment interest. The Company filed a notice of appeal in the fourth quarter of 2004, and a ruling from the appellate court is not anticipated until the first quarter of 2006. Prior to the trial of the U.S. case, various infringement actions and revocation proceedings in the U.K. were consolidated in the Patents Court of the High Court of Justice of England and Wales. This consolidated proceeding is essentially a U.K. counterpart to the U.S. patent action mentioned above. The case went to trial in January 2005, and a ruling from the court is not anticipated until the second quarter of 2005. The Company is defending the allegations and seeking to invalidate the patents involved. Furthermore, outside counsel has advised the Company that any damages that could potentially be shown by the plaintiff in the U.K. case have already been satisfied in the U.S. patent action mentioned above. Although an appeal is underway related to the U.S. case, the Company is continuing to pursue other options, including possible settlement of related claims outstanding. Based on the facts and circumstances and the opinion of outside counsel, management believes that the amounts recognized by the Company reflect the best estimate of its potential loss exposure as disclosed in Note 2. Rose Dove Egle v. John M. Egle, et al. In April 1997, the Company acquired all of the equity interests in Tri-Tech Fishing Services, L.L.C. ("Tri-Tech") in exchange for cash consideration of approximately $20.4 million (the "Transaction"). In August 1998, the Company was added as a defendant in a First Amended Petition filed in the 15th Judicial District Court, Parish of Lafayette, Louisiana entitled Rose Dove Egle v. John M. Egle, et al. In the amended petition, the plaintiffs alleged that, due to an improper conveyance of ownership interest by the Tri-Tech majority partner prior to the Transaction, Smith purchased a portion of its equity interest from individuals who were not legally entitled to their Tri-Tech shares. The suit was tried in the first quarter of 2004, and a jury verdict of approximately $4.8 million was rendered in favor of the plaintiffs. The Company has initiated the appeal process and does not anticipate a ruling from the appellate court until the first quarter of 2006. Based upon the facts and circumstances and the opinion of outside legal counsel, management believes that an unfavorable outcome on this matter is not probable at this time. Accordingly, the Company has not recognized a loss provision in the accompanying consolidated financial statements. 53 Other The Company is a defendant in various other legal proceedings arising in the ordinary course of business. In the opinion of management, these matters will not have a material adverse effect on the Company's consolidated financial position or results of operations. Environmental The Company routinely establishes and reviews the adequacy of reserves for estimated future environmental clean-up costs for properties currently or previously operated by the Company. In connection with most business acquisitions, the Company obtains contractual indemnifications from the seller related to environmental matters. These indemnifications generally provide for the reimbursement of environmental clean-up costs incurred by the Company for events occurring or circumstances existing prior to the purchase date, whether the event or circumstance was known or unknown at that time. A substantial portion of the Company's total environmental exposure is associated with its M-I SWACO operations, which are subject to various indemnifications from former owners. As of December 31, 2004, the Company's environmental reserve totaled $9.0 million. This amount reflects the future undiscounted estimated exposure related to identified properties, without regard to indemnifications from former owners. While actual future environmental costs may differ from estimated liabilities recorded at December 31, 2004, the Company does not believe that these differences will have a material impact on the Company's financial position or results of operations, subject to the indemnifications in place. During 2003, the Company took legal action against M-I SWACO's former owners to clarify certain contractual provisions of the environmental indemnification upon which approximately $8.3 million of remediation costs properly incurred under the indemnification remains unpaid. This matter is expected to go to trial during the second quarter of 2005. In the event that (i) M-I SWACO's former owners and other parties to indemnification agreements with the Company do not fulfill their obligations, and (ii) costs incurred to remediate the identified properties reach estimated maximum exposure limits, the Company would be required to record an additional charge of up to $25.0 million, impacting earnings and cash flows in future periods. 18. QUARTERLY INFORMATION (UNAUDITED) FIRST SECOND THIRD FOURTH YEAR ---------- ---------- ---------- ---------- ---------- (In thousands, except per share data) 2004 Revenues ................................. $1,017,788 $1,064,450 $1,119,184 $1,217,593 $4,419,015 Gross profit ............................. 314,002 327,368 338,983 371,586 1,351,939 Net income ............................... 44,850 27,477 51,893 58,231 182,451 EPS: Basic ................................. 0.44 0.27 0.51 0.57 1.80 Diluted ............................... 0.44 0.27 0.51 0.57 1.78 2003 Revenues ................................. $ 808,837 $ 877,657 $ 924,792 $ 983,542 $3,594,828 Gross profit ............................. 238,343 261,910 278,402 297,276 1,075,931 Income before cumulative effect of change in accounting principle ........ 21,715 29,900 35,004 38,015 124,634 Net income ............................... 20,561 29,900 35,004 38,015 123,480 EPS before cumulative effect of change in accounting principle: Basic ................................. 0.22 0.30 0.35 0.38 1.25 Diluted ............................... 0.22 0.30 0.35 0.38 1.24 54 ITEM 9. CHANGES IN AND DISAGREEMENTS WITH ACCOUNTANTS ON ACCOUNTING AND FINANCIAL DISCLOSURE None. ITEM 9A. CONTROLS AND PROCEDURES The Company maintains disclosure controls and procedures and internal controls designed to provide reasonable assurances that information required to be disclosed in our filings under the Securities Exchange Act of 1934 is recorded, processed, summarized and reported within the time frame specified in the Commission's rules and regulations. Our principal executive and financial officers have evaluated our disclosure controls and procedures and have determined that such disclosure controls and procedures are effective as of the end of the period covered by this report. There has been no change in the Company's internal controls over financial reporting during the quarter ended December 31, 2004 that has materially affected, or is reasonably likely to materially affect, the Company's internal controls over financial reporting. Management's Report on Internal Control over Financial Reporting and the Report of the Independent Registered Public Accounting Firm thereon are set forth in Part II, Item 8 of this report on Form 10-K and are incorporated herein by reference. ITEM 9B. OTHER INFORMATION None. PART III ITEM 10. DIRECTORS AND EXECUTIVE OFFICERS OF THE REGISTRANT For information concerning our directors and Executive Officers, see the information set forth following the caption "PROPOSAL 1: ELECTION OF DIRECTORS" in the Company's definitive proxy statement to be filed no later than 120 days after the end of the fiscal year covered by this Form 10-K (the "Proxy Statement"), which information is incorporated herein by reference. For information concerning our executive officers, see Item 1 appearing in Part I of this Form 10-K. ITEM 11. EXECUTIVE COMPENSATION The information set forth following the caption "EXECUTIVE COMPENSATION" in the Company's Proxy Statement is incorporated herein by reference. ITEM 12. SECURITY OWNERSHIP OF CERTAIN BENEFICIAL OWNERS AND MANAGEMENT The information set forth following the captions "PROPOSAL 1: ELECTION OF DIRECTORS", "STOCK OWNERSHIP OF CERTAIN BENEFICIAL OWNERS" and "Equity Compensation Plan Information" in the Company's Proxy Statement is incorporated herein by reference. ITEM 13. CERTAIN RELATIONSHIPS AND RELATED TRANSACTIONS The information set forth following the captions "PROPOSAL 1: ELECTION OF DIRECTORS" and "EXECUTIVE COMPENSATION" in the Company's Proxy Statement is incorporated herein by reference. ITEM 14. PRINCIPAL ACCOUNTANT FEES AND SERVICES The information set forth following the caption "Fees Paid to Deloitte & Touche LLP" in the Company's Proxy Statement is incorporated herein by reference. 55 PART IV ITEM 15. EXHIBITS, FINANCIAL STATEMENT SCHEDULE AND REPORTS ON FORM 8-K PAGE REFERENCE --------- (a)(1) Financial statements included in this report: Management's Report on Internal Control Over Financial Reporting ................. 26 Reports of Independent Registered Public Accounting Firm ......................... 27 Consolidated Balance Sheets at December 31, 2004 and 2003 ........................ 29 Consolidated Statements of Operations for the years ended December 31, 2004, 2003 and 2002 .............................................. 30 Consolidated Statements of Cash Flows for the years ended December 31, 2004, 2003 and 2002 .............................................. 31 Consolidated Statements of Stockholders' Equity and Comprehensive Income for the years ended December 31, 2004, 2003 and 2002 .......................... 32 Notes to Consolidated Financial Statements ....................................... 33 (2) Financial Statement Schedule II-Valuation and Qualifying Accounts and Reserves ... 59 All other schedules have been omitted since the required information is not present or not present in amounts sufficient to require submission of the schedule or because the information required is included in the consolidated financial statements or notes thereto. (3) Exhibits Exhibits designated with an "*" are filed, and with an "**" furnished, as an exhibit to this Annual Report on Form 10-K. Exhibits designated with a "+" are identified as management contracts or compensatory plans or arrangements. Exhibits previously filed as indicated below are incorporated by reference. 3.1 - Restated Certificate of Incorporation of the Company as amended by Certificate of Amendment of Articles of Incorporation of the Company, dated as of July 8, 1987, and Certificate of Amendment to Restated Certificate of Incorporation of the Company, dated November 17, 1987. Filed as Exhibit 3.1 to the Company's report on Form 10-K for the year ended December 31, 1993 and incorporated herein by reference. 3.2 - Certificate of Amendment to Restated Certificate of Incorporation of the Company, dated May 23, 2001. Filed as Exhibit 3.2 to the Company's Registration Statement on Form S-8 dated July 26, 2001 and incorporated herein by reference. 3.3* - Bylaws of the Company as amended to date. 4.1 - Rights Agreement, dated as of June 8, 2000, between the Company and First Chicago Trust Company of New York, as Rights Agent. Filed as Exhibit 4.1 to the Company's report on Form 8-A, dated June 15, 2000, and incorporated herein by reference. 4.2 - Amendment to Rights Agreement dated June 8, 2000, by and among the Company and First Chicago Trust Company of New York and effective as of October 1, 2001. Filed as Exhibit 4.1 to the Company's report on Form 10-Q for the quarter ended September 30, 2001 and incorporated herein by reference. 4.3 - Amendment No. 2 to Rights Agreement by and among the Company and EquiServe Trust Company, N.A. and effective as of December 31, 2002. Filed as Exhibit 4.3 to the Company's report on Form 10-K for the year ended December 31, 2002 and incorporated herein by reference. 4.4 - Form of Indenture between the Company and The Bank of New York, as Trustee. Filed as Exhibit 4.1 to the Company's Registration Statement on Form S-3 dated August 22, 1997 and incorporated herein by reference. 56 4.5 - Form of Note. Filed as Exhibit 4.2 to Amendment No. 1 to the Company's Registration Statement on Form S-3 dated September 9, 1997 and incorporated herein by reference. 4.6 - Form of Note. Filed as Exhibit 4.1 to the Company's report on Form 8-K dated February 13, 2001 and incorporated herein by reference. 10.1+ - Smith International, Inc. 1989 Long Term Incentive Compensation Plan, as amended to date. Filed as Exhibit 10.1 to the Company's report on form 10-K for the year ended December 31, 2002 and incorporated herein by reference. 10.2+ - Smith International, Inc. Nonqualified Stock Option Agreement as amended to date. Filed as Exhibit 10.2 to the Company's report on Form 8-K dated March 14, 2005 and incorporated herein by reference. 10.3+ - Smith International, Inc. Stock Plan for Outside Directors, as amended and restated effective April 22, 2003. Filed as Exhibit 10.2 to the Company's report on Form 10-K for the year ended December 31, 2003 and incorporated herein by reference. 10.4+ - Smith International, Inc. Supplemental Executive Retirement Plan, as amended to date. Filed as Exhibit 10.1 to the Company's report on Form 10-Q for the quarter ended September 30, 2001 and incorporated herein by reference. 10.5+ - Smith International, Inc. Post-2004 Supplemental Executive Retirement Plan. Filed as Exhibit 10.4 to the Company's report on Form 8-K dated February 28, 2005 and incorporated herein by reference. 10.6+ - Employment Agreement dated December 10, 1987 between the Company and Douglas L. Rock. Filed as Exhibit 10.11 to the Company's report on Form 10-K for the year ended December 31, 1993 and incorporated herein by reference. 10.7+ - Employment Agreement dated January 2, 1991 between the Company and Neal S. Sutton. Filed as Exhibit 10.11 to the Company's report on Form 10-K for the year ended December 31, 1996 and incorporated herein by reference. 10.8+ - Employment Agreement dated May 1, 1991 between the Company and Richard A. Werner. Filed as Exhibit 10.12 to the Company's report on Form 10-K for the year ended December 31, 1996 and incorporated herein by reference. 10.9+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and Douglas L. Rock. Filed as Exhibit 10.11 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 10.10+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and Neal S. Sutton. Filed as Exhibit 10.12 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 10.11+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and Loren K. Carroll. Filed as Exhibit 10.14 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 10.12+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and Margaret K. Dorman. Filed as Exhibit 10.15 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 10.13+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and John J. Kennedy. Filed as Exhibit 10.16 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 57 10.14+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and Roger A. Brown. Filed as Exhibit 10.17 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 10.15 - Credit Agreement dated as of July 10, 2002 among the Company and M-I L.L.C., the Lenders parties thereto and Comerica Bank, as Administrative Agent, ABN AMRO Bank N.V., as Syndication Agent, Den Norske Bank ASA, as Documentation Agent, J.P. Morgan Securities Inc., and Credit Lyonnais New York Branch, as Co-Lead Arrangers and Joint Bookrunners. Filed as Exhibit 10.1 to the Company's report on Form 10-Q for the quarter ended September 30, 2002 and incorporated herein by reference. 14. - Smith International, Inc. Code of Business Conduct and Ethics. Filed as Exhibit 14 to the Company's report on Form 10-K for the year ended December 31, 2003 and incorporated herein by reference. 21.1 - Subsidiaries of the Company. Filed as Exhibit 21.1 to the Company's report on Form 10-K for the year ended December 31, 2002 and incorporated herein by reference. 23.1* - Consent of Independent Registered Public Accounting Firm. 31.1* - Certification of Chief Executive Officer pursuant to Rule 13a-14 or 15d-14 of the Securities Exchange Act of 1934, as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002, filed herewith. 31.2* - Certification of Chief Financial Officer pursuant to Rule 13a-14 or 15d-14 of the Securities Exchange Act of 1934, as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002, filed herewith. 32.1** - Certification Pursuant to 18 U.S.C. Section 1350, as Adopted Pursuant to Section 906 of the Sarbanes-Oxley Act of 2002, furnished herewith. (b) REPORTS ON FORM 8-K The Registrant furnished three reports on Form 8-K during the quarterly period ended December 31, 2004. 1. Form 8-K dated December 10, 2004 relating to an amendment to the Bylaws of Smith International, Inc. adopted December 8, 2004. The document was reported under "Item 5.03. Amendments to Articles of Incorporation or Bylaws; Change in Fiscal Year" and "Item 9.01. Financial Statements and Exhibits." 2. Form 8-K dated December 2, 2004 relating to a press release announcing the Company's appointment of Dod A. Fraser to the Smith International, Inc. Board of Directors on December 1, 2004. The document was reported under "Item 5.02. Departure of Directors or Principal Officers; Election of Directors; Appointment of Principal Officers" and "Item 9.01. Financial Statements and Exhibits." 3. Form 8-K dated October 25, 2004 relating to a press release announcing the Company's results for the quarter ended September 30, 2004. The document was reported under "Item 2.02. Results of Operations and Financial Condition" and "Item 9.01. Financial Statements and Exhibits." 58 SCHEDULE II SMITH INTERNATIONAL, INC. ` VALUATION AND QUALIFYING ACCOUNTS AND RESERVES (IN THOUSANDS) BALANCE AT CHARGED BALANCE BEGINNING TO AT END OF YEAR EXPENSE WRITE-OFFS OF YEAR ---------- ------- ---------- -------- Allowance for doubtful accounts: Year ended December 31, 2004 $12,135 $3,846 $(3,423) $12,558 Year ended December 31, 2003 12,338 3,835 (4,038) 12,135 Year ended December 31, 2002 10,921 9,593 (8,176) 12,338 59 SIGNATURES Pursuant to the requirements of Section 13 or 15(d) of the Securities Exchange Act of 1934, the Registrant has duly caused this report to be signed on its behalf by the undersigned, thereunto duly authorized. SMITH INTERNATIONAL, INC. March 15, 2005 By: /s/ DOUG ROCK ------------------------------------- Doug Rock Chief Executive Officer, President and Chief Operating Officer Pursuant to the requirements of the Securities Exchange Act of 1934, this report has been signed below by the following persons on behalf of the Registrant and in the capacities on the date indicated: /s/ DOUG ROCK Chairman of the Board, March 15, 2005 --------------------------------- Chief Executive Officer, (Doug Rock) President and Chief Operating Officer (principal executive officer) /s/ LOREN K. CARROLL Executive Vice President March 15, 2005 --------------------------------- and Director (Loren K. Carroll) /s/ MARGARET K. DORMAN Senior Vice President, March 15, 2005 --------------------------------- Chief Financial Officer (Margaret K. Dorman) and Treasurer (principal financial and accounting officer) /s/ BENJAMIN F. BAILAR Director March 15, 2005 --------------------------------- (Benjamin F. Bailar) /s/ G. CLYDE BUCK Director March 15, 2005 --------------------------------- (G. Clyde Buck) /s/ DOD A. FRASER Director March 15, 2005 --------------------------------- (Dod A. Fraser) /s/ JAMES R. GIBBS Director March 15, 2005 --------------------------------- (James R. Gibbs) /s/ JERRY W. NEELY Director March 15, 2005 --------------------------------- (Jerry W. Neely) 60 Exhibit Index Exhibits designated with an "*" are filed, and with an "**" furnished, as an exhibit to this Annual Report on Form 10-K. Exhibits designated with a "+" are identified as management contracts or compensatory plans or arrangements. Exhibits previously filed as indicated below are incorporated by reference. 3.1 - Restated Certificate of Incorporation of the Company as amended by Certificate of Amendment of Articles of Incorporation of the Company, dated as of July 8, 1987, and Certificate of Amendment to Restated Certificate of Incorporation of the Company, dated November 17, 1987. Filed as Exhibit 3.1 to the Company's report on Form 10-K for the year ended December 31, 1993 and incorporated herein by reference. 3.2 - Certificate of Amendment to Restated Certificate of Incorporation of the Company, dated May 23, 2001. Filed as Exhibit 3.2 to the Company's Registration Statement on Form S-8 dated July 26, 2001 and incorporated herein by reference. 3.3* - Bylaws of the Company as amended to date. 4.1 - Rights Agreement, dated as of June 8, 2000, between the Company and First Chicago Trust Company of New York, as Rights Agent. Filed as Exhibit 4.1 to the Company's report on Form 8-A, dated June 15, 2000, and incorporated herein by reference. 4.2 - Amendment to Rights Agreement dated June 8, 2000, by and among the Company and First Chicago Trust Company of New York and effective as of October 1, 2001. Filed as Exhibit 4.1 to the Company's report on Form 10-Q for the quarter ended September 30, 2001 and incorporated herein by reference. 4.3 - Amendment No. 2 to Rights Agreement by and among the Company and EquiServe Trust Company, N.A. and effective as of December 31, 2002. Filed as Exhibit 4.3 to the Company's report on Form 10-K for the year ended December 31, 2002 and incorporated herein by reference. 4.4 - Form of Indenture between the Company and The Bank of New York, as Trustee. Filed as Exhibit 4.1 to the Company's Registration Statement on Form S-3 dated August 22, 1997 and incorporated herein by reference. 61 4.5 - Form of Note. Filed as Exhibit 4.2 to Amendment No. 1 to the Company's Registration Statement on Form S-3 dated September 9, 1997 and incorporated herein by reference. 4.6 - Form of Note. Filed as Exhibit 4.1 to the Company's report on Form 8-K dated February 13, 2001 and incorporated herein by reference. 10.1+ - Smith International, Inc. 1989 Long Term Incentive Compensation Plan, as amended to date. Filed as Exhibit 10.1 to the Company's report on form 10-K for the year ended December 31, 2002 and incorporated herein by reference. 10.2+ - Smith International, Inc. Nonqualified Stock Option Agreement as amended to date. Filed as Exhibit 10.2 to the Company's report on Form 8-K dated March 14, 2005 and incorporated herein by reference. 10.3+ - Smith International, Inc. Stock Plan for Outside Directors, as amended and restated effective April 22, 2003. Filed as Exhibit 10.2 to the Company's report on Form 10-K for the year ended December 31, 2003 and incorporated herein by reference. 10.4+ - Smith International, Inc. Supplemental Executive Retirement Plan, as amended to date. Filed as Exhibit 10.1 to the Company's report on Form 10-Q for the quarter ended September 30, 2001 and incorporated herein by reference. 10.5+ - Smith International, Inc. Post-2004 Supplemental Executive Retirement Plan. Filed as Exhibit 10.4 to the Company's report on Form 8-K dated February 28, 2005 and incorporated herein by reference. 10.6+ - Employment Agreement dated December 10, 1987 between the Company and Douglas L. Rock. Filed as Exhibit 10.11 to the Company's report on Form 10-K for the year ended December 31, 1993 and incorporated herein by reference. 10.7+ - Employment Agreement dated January 2, 1991 between the Company and Neal S. Sutton. Filed as Exhibit 10.11 to the Company's report on Form 10-K for the year ended December 31, 1996 and incorporated herein by reference. 10.8+ - Employment Agreement dated May 1, 1991 between the Company and Richard A. Werner. Filed as Exhibit 10.12 to the Company's report on Form 10-K for the year ended December 31, 1996 and incorporated herein by reference. 10.9+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and Douglas L. Rock. Filed as Exhibit 10.11 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 10.10+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and Neal S. Sutton. Filed as Exhibit 10.12 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 10.11+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and Loren K. Carroll. Filed as Exhibit 10.14 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 10.12+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and Margaret K. Dorman. Filed as Exhibit 10.15 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 10.13+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and John J. Kennedy. Filed as Exhibit 10.16 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 62 10.14+ - Change-of-Control Employment Agreement dated January 4, 2000 between the Company and Roger A. Brown. Filed as Exhibit 10.17 to the Company's report on Form 10-K for the year ended December 31, 1999 and incorporated herein by reference. 10.15 - Credit Agreement dated as of July 10, 2002 among the Company and M-I L.L.C., the Lenders parties thereto and Comerica Bank, as Administrative Agent, ABN AMRO Bank N.V., as Syndication Agent, Den Norske Bank ASA, as Documentation Agent, J.P. Morgan Securities Inc., and Credit Lyonnais New York Branch, as Co-Lead Arrangers and Joint Bookrunners. Filed as Exhibit 10.1 to the Company's report on Form 10-Q for the quarter ended September 30, 2002 and incorporated herein by reference. 14. - Smith International, Inc. Code of Business Conduct and Ethics. Filed as Exhibit 14 to the Company's report on Form 10-K for the year ended December 31, 2003 and incorporated herein by reference. 21.1 - Subsidiaries of the Company. Filed as Exhibit 21.1 to the Company's report on Form 10-K for the year ended December 31, 2002 and incorporated herein by reference. 23.1* - Consent of Independent Registered Public Accounting Firm. 31.1* - Certification of Chief Executive Officer pursuant to Rule 13a-14 or 15d-14 of the Securities Exchange Act of 1934, as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002, filed herewith. 31.2* - Certification of Chief Financial Officer pursuant to Rule 13a-14 or 15d-14 of the Securities Exchange Act of 1934, as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002, filed herewith. 32.1** - Certification Pursuant to 18 U.S.C. Section 1350, as Adopted Pursuant to Section 906 of the Sarbanes-Oxley Act of 2002, furnished herewith. 63