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3. DETAILED COST INVESTIGATIONS
3.1. Update of previous investigations
 
In order to collect the necessary, data, the Commission has recourse to consultants whose ongoing study has defined a cost breakdown model, including all relevant cost components both of the direct ship production and the shipyard in general. The model is based on cost elements covering direct costs (materials, labour, equipment, etc.)and indirect costs (financing of the ship and of the production equipment, overhead, insurance, etc.). The calculated building price also includes a 5 % profit margin. More details of the cost model can be found in Annex I of the first report.
 
As the study develops, additional information is gathered and used to validate previous cost investigations. Consequently, the 25 orders placed in Korea covered in the first three reports have been recalculated and the updated findings are given below. As already stated in the first report all parameters are based on a prudent approach to ensure that calculated minimum costs for particular projects will be difficult to challenge. The updated analysis includes assumptions on inflation. With orders taken now but executed in the coming two to three years it is considered normal business practice to assess future costs at the time of building up to delivery.
 
In the context of the first shipbuilding report nine orders placed at South Korean shipyards were investigated. In addition to these orders, 9 more orders placed in Korea have been analysed for the second report and 7 investigations were added in the third report. The Commission ensured a balanced selection of shipbuilding contracts while taking into account the overall objective of the exercise, the relative urgency of the matter, and the availability of meaningful data for comparison. The Commission is convinced that the information entered into the analysis is at present the best available and reliable.
 
The following table summarises the updated findings for the 25 orders placed in Korea.
Table 4 - Comparison of order prices and calculated construction prices for selected new shipbuilding contracts (update)
i
  Shipyard Shiptype Owner Container price (Mio.USD) Normal price (Mio.USD) Loss/gain as % of normal price
  Daedong 35000 dwt tanker Seaarland 21,5 25,8 -17%
  Daedong Panamax bulker Sanama 18,5 26,1 -29%
  Daedong 46000 dwt chemical tanker Cogema 24,5 30,1 -19%
  Daewoo VLCC Anangel 68,5 73,6  -7%
  Daewoo Ferry Moby 74,3 89,0 -17%
(*) Daewoo Pnamax bulker Chandris 22,5 23,5   -4%
(*)/(**) Halla Pnamax bulker Diana 18,9 31,0 -39%
(*) Halla 3500 TEU Detjen 38,0 52,8 -28%
(*) Halla Capesize bulker Cargocean 32,0 45,8 -30%
(*) HHI 6800 TEU P&O Nedlloyd 73,5 81,0   -9%
(*) HHI 5600 TEU K Line 54,3 59,3   -8%
(*) HHI LNG carrier Bonny Gas 165,0 182,5 -10%
(*) HHI 5500 TEU Yang Ming 56,0 64,6 -13%
  Mipo Cable layer Ozone 37,3 46,8 -20%
  Il Heung 3700 dwt chemical tanker Naviera Quimica 10,5 13,0 -19%
  Samsung 5500 TEU Nordcapital 55,0 71,5 -23%
  Samsung 3400 TEU CP Offen 36,0 59,2 -39%
  Samsung Ferry Minoan 69,5 94,9 -27%
  HHIC 6250 TEU Conti 62,0 62,7   -1%
  HHIC 5608 TEU Conti 58,0 59,1  -2%
  HHIC 1200 TEU Rickmers 19,5 20,4  -4%
(***) HHI 7200 TEU Hapag-Lloyd 72,0 81,0 -11%
  HHI Suezmax tanker Athenian Sea Carriers 43,0 50,8 -7%
  Daewoo LNG carrier Bergesen 151,1 148,3 +2%
  Shina Product tanker Fratelli D'Amato 21,7 24,1 -10%
(*) These orders were also recalculated alter new information on the debt situation of the companies was received.
(**) This order was recalculated after the correct contract price was revealed in the owner's account statement for 2000.
(***) This order was recalculated after the correct contract price was revealed in the press.
It should be noted that in no case has the model concluded that any of the contracts examined has been priced at an economically viable level, that is to say covering direct costs, plus an appropriate contribution to overhead costs, plus an appropriate contribution to debt servicing (i.e. repayment of principal plus interest), plus an element of profit. The order for an LNG carrier at Daewoo shows a marginal profit, but only after the massive debt reduction of nearly 80 %, granted to the yard in autumn 2000, was factored in.
 
In most of the contracts investigated, prices have also failed to reach the break-even level (i.e. the normal price excluding profit). On average the losses taken by Korean yards with regard to these orders are ca. l6 % of the actual building costs, when inflation is factored in. Some orders may be close to profitability, but these concern shipyards that have been able to reduce their debts, either through the issuing of new shares (HHI) or through debt restructuring. (deferred repayments, moratoria on interest, write-offs, debt-equity swaps) as it is the case with Daewoo and Halla/Samho. The Commission is examining the compatibility of the new debt situation with WTO provisions in the context of the separate TBR investigation.
 
3.2. New investigations
 
Since the Commission's last report seven more detailed cost investigations for orders placed in Korean yards were undertaken. The aim of these investigations was to cover as much of the Korean shipbuilding industry as possible, looking at specific orders that would have been of interest to EU yards. The following orders were investigated:
 
- Ferry (series of 2), 39 600 cgt, to be built at Hyundai Heavy Industries (HHI);
 
- 7 400 TEU containership (series of 2), 57 850 cgt, to be built at Samsung Heavy Industries (SHT);
 
- Suezmax crude oil (series of 6), 38 250 cgt, to be built at Hyundai Heavy Industries (HHl);
 
- 2 500 TEU containership (series of 3), 20 844 cgt, to be built at Daedong Shipbuilding Co. Ltd.;
 
- Chemical tanker (series of 4), 20 800 cgt, to be built at Hyundai Mipo;
 
- Aframax crude oil tanker (series of 4), 26 650 cgt, to be built at Samho Heavy Industries (SHI);
 
- Ultra Large Crude Oil Carrier (series of 4), 70 500 cgt, to be built at Daewoo Shipbuilding and Marine Engineering (DSME).
 
Table 5 summarises the findings from the new cost investigations.
Table 5 - Comparison of order prices and calculated construction prices for selected new ships (new investigations)
Shipyard Shiptype Owner Contract price (Mio,USD) Normal
price
(Mio,USD)
Loss/gain as% of normal price
HHI Ferry Stena 70,0 88,4 -21%
SHI 7 400 TEU OOCL 79,7 94,1 -15%
HHI Suezmax tanker Jebsen 43,0 51,5 -17%
Daedong 2 500 TEU EF Shipping 30,0 31,4  -4%
Mipo Chemical tanker Bottiglieri 24,5 27,3 -10%
SHI Aframax tanker Chartworld Shipping 33,5 41,3 -19%
DSME ULCC Hellespont 85,0 94,0 -10%
 
Losses taken for these newly investigated orders are on average 14 %, as compared to average losses of l6 % for the previously investigated orders. The reasons for this "improvement" are to be found in slightly higher contract prices, in particular for tankers, and, most of al1, in a significant restructuring of the company debts, leading either to lower debt levels or to longer repayment periods, thus stretching the debts over more contracts. As stated in the third report, the recognition of these changes in company debts does not mean that the Commission accepts the new debt situation as such in terms of its compatibility with WTO provisions.
 
Concerning the order for a ferry at Hyundai Heavy Industries (HHI), the cost evaluation concluded that the price had been set below operating cost level. Even without taking inflation into account, the contract would make a considerable loss at the operating level and no provision is included for debt repayment. This is likely to be a significantly loss-making contract for HHI. Stena has in the past been an owner who ordered vessels, including ferries, with a number of yards in the EU and in Far East. Ships similar to the one investigated were in the past ordered by Stena in Korea, in Finland and in Spain. Therefore, and given that at least one EU yard actually tendered for the contract, it can be concluded that this order should have been within reach of EU shipbuilders and it was the very low price which ultimately brought the contract to Korea. Consequently this contract has to be seen as injurious to EU shipyards.
 
For the containership of 7 400 TEU to be built at Samsung Heavy Industries the model calculation concludes that the contract is priced at the operating cost level(including provision for inflation), and makes no contribution to below the line expenses, in particular servicing debt. It should be noted that the amount calculated for servicing debt includes provision for interest payment only and does not provide for the generation of cash to repay principal. It has been assumed that Samsung will continue to refinance (i.e. roll over) debt in this situation, rather than making repayments as planned. It is therefore concluded that the price of the contract does not meet two of the aims of the company, as outlined in Samsung's plans set out in February 2001 in a document from Samsung Securities. Firstly the company forecasts a return to substantial profitability in 2002, following forecast losses in 2001. The price does not support that forecast. Secondly significant reduction of debt is also forecast and again the results do not support that forecast.
 
With regard to the order for six Suezmax tankers at Hyundai Heavy Industries the results of the cost evaluation confirm previous results for HHI, i.e. that the price does not include sufficient provision for inflation and makes no contribution to debt servicing. The implications of this conclusion are that the profitability of the company is likely to continue to decline, rather than recovering as forecast by Hyundai. It is possible that further refinancing may be needed in future if HHI is unable to meet its debt commitments. Seven other orders of this shiptype at around this price were placed at HHI over the first six months of the current monitoring phase.
 
For the containership order at Daedong Shipbuilding Co. Ltd. the cost evaluation concludes that the contract has not been taken on a profitable basis, and may only reach the break-even level. This indicates a slight departure from previous contracts examined at Daedong which were highly loss-making. The shipyard has been specifically helped to achieve this improved result by a number of factors:
 
- Following bankruptcy the shipyard is operating under a moratorium on the servicing of debt that effectively means the cost of facilities is very low;
 
- the ships are for delivery in this year or mid 2002, and inflation effects are therefore limited;
 
- the shipyard operates at a significantly lower level of overhead than the larger yards in South Korea;
 
- Daedong has modern purpose-built facilities that lead to a high level of performance.
 
In addition to these specific factors it also has to be said that the price of the ship is relatively good, in particular in relation to the larger container ships being pursued by the larger shipyards. It should also be noted that Daedong, still being under court receivership, is obliged to accept only, as a matter of principle, profitable contracts in order to recover its economic viability.
 
Concerning the order for chemical tankers placed at Hyundai Mipo yard the cost evaluation gave the result that the price covers operating costs and inflation, but will make no contribution to debt servicing. Whilst the level of debt at Hyundai Mipo is lower than the large South Korean shipyards, a considerable debt has been accumulated in developing shipbuilding facilities (the yard has previously been active in ship repair only). At this price level it is likely that re-financing will be required. Future profitability is doubtful, bearing in mind that this result will be typical of the shipyards orderbook and that early contracts in this series were taken at a lower price and are therefore likely to be loss making.
 
With regard to the order for Aframax tankers, placed at Samho Heavy Industries, results of the cost evaluation reveal that the price taken for this ship is better than those previously examined but that it is still below an economically viable level and makes no contribution to servicing Samho's debts. Previous analysis for contracts at Halla/Samho concluded that whilst massive debt restructuring had enabled the shipyard to reduce contract costs by about 6 %, the prices of contracts remained far below an economically viable level. Even given the higher price negotiated by HHI for the two optional contracts (34 Mio. USD), the price falls marginally below the calculated operating cost, and the contract does not appear to include any provision for debt servicing. It should also be noted that no provision is included for management fees for HHI and this will increase the operating loss further.
 
In the case of the Ultra Large Crude Oil Carrier, ordered by Hellespont at Daewoo Shipbuilding and Marine Engineering, the cost evaluation concludes that the price covers operating costs only, without making a significant contribution to debt servicing commitments of the company following restructuring. This confirms previous conclusions for Daewoo that the price of contracts is insufficient to generate an operating profit and to service the company's debt commitments, even after significant restructuring. This is despite assumptions for very high levels of performance at Daewoo.
4. CONCLUSIONS
 
This fourth report confirms the finding of the first three reports.
 
The year 2000 has seen a significant expansion in orders for new ships. Nearly 56 %more orders were placed as compared to 1999. The larger part of this increase in ordering has been to the benefit of South Korean shipyards which have seen market share increase again. EU yards also benefited considerably from the higher demand for ships, although orders for cruise ships may have played a dominant role here. In 2000, South Korea has consolidated its position as the largest shipbuilding country/region in the world, accounting for more than 35 % of all tonnage ordered world-wide.
 
The market share for the EU shipbuilding industry has remained stable in 2000 as losses in some market segments were compensated by additional orders for cruise ships. Half of the volume (in cgt) produced in Europe in 2000 concerns these ships for which there is as yet no Far East competition. Including cruise ships, the market share for the EU and Norway is ca. 18 % (in cgt). If orders for cruise ships are excluded from the overall figures, the market share of EU yards for new orders in 2000 is below 10 %.
 
In 2000 prices for new ships were reported to recover in certain market segments from the very low levels seen after the Asian crisis in 1997. Prices in South Korean shipyards have been monitored on a contract by contract basis by the Commission. The analysis clearly shows that the upward tendency of prices seen in autumn 2000 was not sustained, leading to the conclusion that overall price levels have not recovered and are still significantly lower than before the Asian crisis of 1997. There are no indications that Korean shipbuilders managed to raise price levels across the board as repeatedly announced by Korean sources. Therefore the Commission maintains its view that significant over-capacities in South Korean shipbuilding, combined with an ongoing need to generate new orders in order to assure sufficient cash flow, prevent a recovery of prices and the market in general.
 
Since the Commission's last report, seven more detailed cost investigations for orders placed in Korean yards have been undertaken. In no case it has been concluded that any of the contracts examined has been priced at an economically viable level, i.e. covering operating costs, profits and debt repayments. Losses, calculated in this way, on these newly investigated orders are 14 % on average.
 
The Commission will, in line with its obligations arising from the reporting requirements in Council Regulation (EC) No l540/98, continue its market monitoring and cost investigations.
5. REFERENCES
 
Council Regulation (EC) No 1540/98 of 29 June 1998 establishing new rules on aid to shipbuilding, Officia1 Journal L 202, 18.7.1998 p. 0001-0010
 
Report from the Commission to the Council on the situation in world shipbuilding, COM(1999) 474 final of 13.10.1999
 
Second Report from the Commission to the Council on the situation in world shipbuilding, COM(2000) 263 final of 3.5.2000
 
Third Report from the Commission to the Council on the situation in world shipbuilding, COM(2000) 730 final of 15. 1 1.2000
 
Council Regulation (EC) No 3286/94 of 22 December 1994 laying down Community procedures in the field of the common commercial policy in order to ensure the exercise of the Community's rights under international trade rules, in particular those established under the auspices of the World Trade Organization, Official Journal L 349, 31.12.1994 p. 0071-0078
 
OECD "Agreement Respecting Normal Competitive Conditions in the Commercial Shipbuilding and Repair Industry", Final Act signed in December 1994 by the Commission of the European Communities, and the Governments of Finland, Japan, the Republic of Korea, Norway, Sweden and the United States
 
OECD "Understanding on export credits for ships", 1994.








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