SUN SPORTSWEAR INC
10-Q, 1996-08-13
WOMEN'S, MISSES', AND JUNIORS OUTERWEAR
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<PAGE>   1
                       SECURITIES AND EXCHANGE COMMISSION
                             WASHINGTON, D.C. 20549
                                    FORM 10-Q



(Mark one)


[X]      QUARTERLY REPORT UNDER SECTION 13 OR 15(d) OF THE SECURITIES AND
         EXCHANGE ACT OF 1934

For the Quarterly period ended JUNE 30, 1996

                                       OR

[ ]      TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES
         AND EXCHANGE ACT OF 1934


For the transition period from ____________________ to ____________________

Commission File Number    0-18054


                              SUN SPORTSWEAR, INC.
             (Exact name of registrant as specified in its charter)


         WASHINGTON                                         91-1132690
(State or other jurisdiction                              (IRS Employer
   of incorporation of                                  Identification No.)
   organization)


6520 SOUTH 190TH STREET, KENT, WASHINGTOn                      98032
(Address of principal executive offices)                    (Zip Code)


(206) 251-3565
(Registrant's telephone number
 including area code)


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 and 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
                                   ---    ---

As of August 9, 1996 the Registrant had 5,748,500 shares of common stock
outstanding.



                                  Page 1 of 13
<PAGE>   2




                              SUN SPORTSWEAR, INC.

                                      INDEX


                                                                         Page
Part I.            Financial Information

         Item 1.        Financial Statements:

                        Balance Sheets at June 30, 1996                    3-4
                        (unaudited) and December 31, 1995


                        Statements of Income                               5
                        for the three months ended
                        June 30, 1996 and 1995 (unaudited) and for
                        the six months ended June 30, 1996 and 1995
                        (unaudited)

                        Statements of Cash Flows                           6
                        for the six months ended June 30,
                        1996 and 1995 (unaudited)

                        Notes to Financial Statements                      7-8

         Item 2.        Management's Discussion and Analysis               8-12
                        of Financial Condition and Results
                        of Operations

Part II.           Other Information

         Item 1.        Legal Proceedings                                  12

         Item 2.        Changes in Securities                              12

         Item 3.        Defaults upon Senior Securities                    12

         Item 4.        Submission of Matters to a Vote of                 12
                        Security Holders

         Item 5.        Other Information                                  12

         Item 6.        Exhibits and Reports on Form 8-K                   12


Signature Page                                                             13



                                  Page 2 of 13
<PAGE>   3

                              SUN SPORTSWEAR, INC.
                                 BALANCE SHEETS

<TABLE>
<CAPTION>
                                                      JUNE 30,      DECEMBER 31, 
                                                       1996             1995
                                                    -----------     -----------
                                                    (UNAUDITED)
<S>                                                 <C>             <C>        
    ASSETS

CURRENT ASSETS:
         Cash                                       $   111,094     $ 2,006,633
         Accounts receivable, net of
           allowance for doubtful accounts of
           $45,904 and $46,317, respectively         16,133,426      13,102,275
         Inventories, net (Note 2)                   18,766,448      23,631,358
         Prepaid expenses and other
           current assets                             1,054,264         959,872
         Deferred income taxes                          788,332         788,332
         Federal income tax receivable                  247,387       1,979,535
                                                    -----------     -----------

         Total current assets                        37,100,951      42,468,005

EQUIPMENT AND LEASEHOLD IMPROVEMENTS, NET
         (Note 3)                                     4,384,122       4,831,994

OTHER ASSETS                                             14,500          15,107
                                                    -----------     -----------
         Total assets                               $41,499,573     $47,315,106
                                                    ===========     ===========
</TABLE>




                                   (continued)
                 See accompanying notes to financial statements



                                  Page 3 of 13
<PAGE>   4

                              SUN SPORTSWEAR, INC.

                                 BALANCE SHEETS
                                   (CONTINUED)

<TABLE>
<CAPTION>
                                                     JUNE 30,       DECEMBER 31, 
                                                      1996              1995
                                                  ------------      -----------
                                                  (UNAUDITED)

<S>                                               <C>               <C>        
         LIABILITIES AND 
         SHAREHOLDERS' EQUITY

CURRENT LIABILITIES:
         Notes payable                            $ 7,349,470       $13,500,000
         Accounts payable                           5,300,123         4,985,953
         Accrued royalties payable                  1,776,377         1,753,745
         Accrued wages and taxes payable              557,694           512,078
         Accrued interest payable                      54,851            51,263
         Current portion of long-term debt                -0-           245,652
                                                  -----------       -----------

         Total current liabilities                 15,038,515        21,048,691
                                                  -----------       -----------

NONCURRENT LIABILITIES:
         Long-term debt,
           net of current portion                         -0-            92,354
         Deferred income taxes                        155,642           155,642
                                                  -----------       -----------

         Total noncurrent liabilities                 155,642           247,996
                                                  -----------       -----------

SHAREHOLDERS' EQUITY:
         Common stock, no par value,
           20,000,000 shares authorized;
           5,748,500 shares at 6/30/96
           and 5,748,500 shares at 12/31/95
           issued and outstanding                  21,618,339        21,618,339
         Retained earnings                          4,687,077         4,400,080
                                                  -----------       -----------

         Total shareholders' equity                26,305,416        26,018,419
                                                  -----------       -----------

COMMITMENTS AND
  CONTINGENCIES
         Total liabilities and
           shareholders' equity                   $41,499,573       $47,315,106
                                                  ===========       ===========
</TABLE>


                 See accompanying notes to financial statements



                                  Page 4 of 13
<PAGE>   5
                              SUN SPORTSWEAR, INC.

                              STATEMENTS OF INCOME
                                   (UNAUDITED)

<TABLE>
<CAPTION>
                                     FOR THE THREE MONTHS ENDED               FOR THE SIX MONTHS ENDED
                                               JUNE 30,                                JUNE 30,
                                  --------------------------------        --------------------------------
                                       1996                1995               1996                 1995
                                  ------------        ------------        ------------        ------------
<S>                               <C>                 <C>                 <C>                 <C>         
Proprietary sales                 $  5,703,323        $  4,397,014        $ 10,325,687        $ 10,429,871
Licensed sales                      14,762,315          26,791,188          35,221,953          47,347,630
Sales deductions                      (431,073)           (606,697)         (1,079,635)         (1,475,434)
                                  ------------        ------------        ------------        ------------

Net sales (Note 4):                 20,034,565          30,581,505          44,468,005          56,302,067
Cost of goods sold                  16,871,903          25,310,087          37,495,432          47,832,585
                                  ------------        ------------        ------------        ------------
Gross margin                         3,162,662           5,271,418           6,972,573           8,469,482
                                  ------------        ------------        ------------        ------------
Operating expenses:
     Selling                           741,110             899,060           1,516,179           1,886,685
     Design and pattern                681,697             614,839           1,343,958           1,258,982
     General and
       administrative                1,514,732           2,132,007           3,227,429           4,114,003
     Provision for doubtful
       accounts and
       factoring fees                   46,513              16,189              78,484              29,853
                                  ------------        ------------        ------------        ------------
                                     2,984,052           3,662,095           6,166,050           7,289,523
                                  ------------        ------------        ------------        ------------

Operating income                       178,610           1,609,323             806,523           1,179,959
                                  ------------        ------------        ------------        ------------

Other expense (income):
     Interest expense                  176,390             360,735             417,381             705,053
     Other, net                        (27,052)            (46,702)            (44,856)            (60,987)
                                  ------------        ------------        ------------        ------------
                                       149,338             314,033             372,525             644,066
                                  ------------        ------------        ------------        ------------

Income before provision
  for income taxes                      29,272           1,295,290             433,998             535,893
Provision for
  income taxes                           9,000             440,000             147,000             182,000
                                  ------------        ------------        ------------        ------------

Net income                        $     20,272        $    855,290        $    286,998        $    353,893
                                  ============        ============        ============        ============

Earnings per share:               $       0.00        $       0.15        $       0.05        $       0.06
                                  ============        ============        ============        ============

Weighted average shares              5,748,500           5,748,451           5,748,500           5,747,997
  outstanding
</TABLE>







                 See accompanying notes to financial statements

                                  Page 5 of 13
<PAGE>   6
                              SUN SPORTSWEAR, INC.

                            STATEMENTS OF CASH FLOWS
                                   (UNAUDITED)

<TABLE>
<CAPTION>
                                                               FOR THE SIX MONTHS ENDED JUNE 30,
                                                                   1996                1995
                                                               -----------        -------------
<S>                                                            <C>                <C>        
Cash flows from operating activities:
     Net income                                                $   286,998        $   353,893
     Adjustments to reconcile net income to net cash
       provided by (used in) operating activities:
         Depreciation and amortization                             806,787            738,815
         Gain on disposal of equipment                             (10,196)            (5,984)
         Increase in accounts receivable                        (3,031,151)           (77,647)
         Decrease in inventories                                 4,864,910          4,614,177
         Decrease (increase) in federal
           income tax receivable, accrued and deferred           1,732,148           (109,000)
         (Decrease) increase in other assets                       (93,785)           188,365
         Increase (decrease) in accounts payable                   165,867         (6,178,832)
         Increase (decrease) in accrued liabilities                 71,836            (60,003)
                                                               -----------        -----------
     Net cash provided by (used in) operating activities         4,793,414           (536,216)
                                                               -----------        -----------

Cash flows from investing activities:
     Capital expenditures                                         (359,827)          (812,458)
     Proceeds from sale of equipment                                11,108             34,015
                                                               -----------        -----------
     Net cash used in investing activities                        (348,719)          (778,443)
                                                               -----------        -----------

Cash flows from financing activities:
     Increase (decrease) in outstanding
       checks in excess of funds on deposit                        148,303         (1,138,604)
     Net (repayments) borrowings
       under line of credit agreement                           (6,150,530)         1,655,000
     Principal payments under long-term debt                      (338,007)          (137,517)
     Proceeds from issuance of common
       stock for employee stock options                                -0-              4,648
                                                               -----------        -----------
     Net cash (used in) provided by financing activities        (6,340,234)           383,527
                                                               -----------        -----------

Net decrease in cash                                            (1,895,539)          (931,132)
Cash at beginning of period                                      2,006,633          1,217,171
                                                               -----------        -----------
Cash at end of period                                          $   111,094        $   286,039
                                                               ===========        ===========

SUPPLEMENTAL DISCLOSURE OF CASH FLOW INFORMATION:
Cash paid (received) during the period for:
         Interest                                              $   413,792        $   708,775
         Income taxes                                          ($1,585,148)       $   291,000
</TABLE>








                 See accompanying notes to financial statements


                                  Page 6 of 13
<PAGE>   7
                              SUN SPORTSWEAR, INC.
                          NOTES TO FINANCIAL STATEMENTS

NOTE 1 - SIGNIFICANT ACCOUNTING POLICIES: 
INTERIM FINANCIAL STATEMENTS 
The accompanying financial statements at June 30, 1996 for the three and six
months ended June 30, 1996 and June 30, 1995 are unaudited. These unaudited
interim financial statements and related notes have been prepared pursuant to
the rules and regulations of the Securities and Exchange Commission. 
Accordingly, certain information and footnote disclosures normally included in
financial statements prepared in accordance with generally accepted accounting
principles have been omitted pursuant to such rules and regulations. However, in
the opinion of management, the accompanying condensed financial statements
include all adjustments, consisting only of normal recurring accruals, necessary
for a fair statement of the results for the interim periods. The results of
operations and cash flows for the six months ended June 30, 1996 and 1995 are
not necessarily indicative of the results of operations and cash flows that may
be expected for the entire year, which are subject to year-end adjustments in
conjunction with the annual audit by the Company's independent public
accountants. The accompanying condensed financial statements and related notes
should be read in conjunction with the financial statements and footnotes
thereto included in Sun Sportswear, Inc.'s (the "Company") 1995 Form 10-K and
Annual Report to Shareholders. See also "Item 2 - Management's Discussion and
Analysis of Financial Condition and Results of Operations Quarterly Net Sales -
Seasonality" on page 11 of this report.

NOTE 2 - INVENTORIES:
         Inventories are composed as follows:
<TABLE>
<CAPTION>

                                          June 30,         December 31,
                                            1996               1995
                                        ------------       -------------

<S>                                     <C>                 <C>         
Garments in process                     $  2,251,396        $  2,244,781
Unprinted finished garments               16,307,466          19,827,823
Printed finished garments                  2,257,446           5,617,347
Supplies                                     931,689             407,064
Lower of cost or market allowance         (2,981,549)         (4,465,657)
                                        ------------       -------------
                                        $ 18,766,448        $ 23,631,358
                                        ============        ============
</TABLE>

NOTE 3 - EQUIPMENT AND LEASEHOLD IMPROVEMENTS:
Equipment and leasehold improvements are summarized by major classifications as
follows:

<TABLE>
<CAPTION>

                                           Estimated        June 30,          December 31,
                                          useful lives        1996                1995
                                          ------------    ------------        ------------   
<S>                                       <C>             <C>                 <C>         
Production equipment                           5-7        $  3,791,581        $  3,658,861
Leasehold improvements                         5-10          1,286,329           1,271,542
Design system hardware and software            3-5             954,333             851,056
Information system hardware and software       3-5           1,889,172           2,145,582
Furniture and fixtures                          5            1,052,506           1,116,112
Distribution equipment                         5-10          1,481,340           1,452,716
Warehouse equipment                            5-7             385,201             395,797
Vehicles                                        5               12,417              12,417
                                                          ------------        ------------
                                                            10,852,879          10,904,083
LESS - Accumulated depreciation                             (6,468,757)         (6,072,089)
                                                          ------------        ------------
                                                          $  4,384,122        $  4,831,994
                                                          ============        ============
</TABLE>


                                  Page 7 of 13

<PAGE>   8


NOTE 4 - MAJOR CUSTOMERS:
The Company operates almost exclusively in one industry, which is the wholesale
distribution of imprinted, dyed and decorated casual apparel. The Company has
three major customers, all of whom are mass merchants. The percentage of gross
sales for each customer and the total percentage of gross sales for the three
customers are as follows:

<TABLE>
<CAPTION>
                                                Percentage of gross sales for     Total percentage
                                                 the Company's three largest     of gross sales for
                                                          customers              the three customers
<S>                                             <C>                              <C> 
       For the six months ended June 30,
                1996                                  12%, 25% and 48%                   85%
                1995                                  19%, 27% and 41%                   87%

       For the year ended December 31, 1995           17%, 24% and 47%                   88%
</TABLE>


ITEM 2. MANAGEMENT'S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS
        OF OPERATIONS

RESULTS OF OPERATIONS
         The following table sets forth, for the periods indicated, the
percentage relationship of certain income statement items to net sales and the
dollar increase or decrease as a percentage of such items from period to period:

<TABLE>
<CAPTION>
                                                                                    ---------------------            
                                                                                            Dollar                    
                                                                                      (decrease)/increase             
                                                                                        as a percentage               
                                                                                         1995 to 1996                               
                              -------------------        --------------------       --------------------- 
                                  Three months             Six months ended          three          six
                                 ended June 30,                 June 30,             months        months      
                              -------------------        --------------------        ended         ended 
                              1996          1995          1996          1995        June 30,      June 30,
                              ----          ----          ----          ----        -------       -------
<S>                          <C>           <C>           <C>           <C>          <C>           <C>   
Gross sales
     Proprietary sales        28.5%         14.4%         23.2%         18.5%         29.7%         (1.0)%
     Licensed sales           73.7          87.6          79.2          84.1         (44.9)        (25.6)
Sales deductions              (2.2)         (2.0)         (2.4)         (2.6)        (28.9)        (26.8)
                             -----         -----         -----         -----
Net sales                    100.0         100.0         100.0         100.0         (34.5)        (21.0)

Cost of goods sold            84.2          82.8          84.3          85.0         (33.3)        (21.6)
Gross margin                  15.8          17.2          15.7          15.0         (40.0)        (17.7)
Operating expenses            14.9          12.0          13.9          12.9         (18.5)        (15.4)
Interest expense               0.9           1.2           0.9           1.3         (51.1)        (40.8)
Other (income)
  and expense                 (0.1)         (0.2)         (0.1)         (0.1)        (42.1)        (26.4)
Provision (benefit)
  for income taxes             0.0           1.4           0.3           0.3         (98.0)        (19.2)
                             -----         -----         -----         -----

Net income                     0.1%          2.8%          0.7%          0.6%        (97.6)        (18.9)
                             =====         =====         =====         =====
</TABLE>


SECOND QUARTER OF 1996 AND SECOND QUARTER OF 1995
NET SALES. Net sales for the quarter ended June 30, 1996 decreased 34% to $20.0
million from $30.6 million in the same period of 1995. Gross sales of men's and
boys' products decreased 44% to $4.7 million in the second quarter of 1996 from
$8.4 million in the same period of 1995. Women's and girls' gross sales
decreased by 31% to $15.7 million in the second quarter of 1996 from $22.7
million in the same period of 1995. The Company believes these sales decreases
were the result of the soft retail environment. 


                                  Page 8 of 13

<PAGE>   9


The Company expects its third quarter 1996 sales to be below its third quarter
1995 sales as a result of this soft retail environment (see "Quarterly Net 
Sales - Seasonality" below).

         The Company is working to improve its results by focusing on new
customers, on the private label needs of its mid-tier and mass market customers,
and building its men's and boys' business. To assist in these efforts, the
Company is in the process of upgrading and enlarging its sales staff, has
recently begun a formal program of new customer development and is expanding its
product design capabilities to encompass private label business.

         Gross sales of licensed products decreased to $14.8 million in the
second quarter of 1996 versus $26.8 million in the second quarter of 1995. The
Company believes this sales decrease was the result of the soft retail
environment.

         The Company, on an ongoing basis, is actively seeking additional
licenses and brands to add to its existing stable of licensed properties. Recent
license acquisitions include Disney Enterprises' 1996 live action movie release,
101 Dalmatians((C) Disney) and a Budweiser(R) license from Anheuser-Busch. There
can be no assurances, however, that any license acquisitions will receive
positive market acceptance by Sun's customers.

         The Company is currently negotiating to renew its two top selling
licenses, both of which expire at the end of 1996 (these two licenses accounted
for 26% and 25% of the Company's gross revenues in the first six months of
1996). While the Company hopes to renew these and other licenses, there can be
no assurance that any license held by the Company will be renewed by the
licensor.

         Gross sales of proprietary products increased by 30% to $5.7 million in
the 1996 quarter from $4.4 million in the 1995 quarter. The Company believes
this increase was primarily the result of the Company's concerted effort to
increase its private label business with such customers as J.C. Penneys (Arizona
Jeans(R) label) and Sears (Canyon River Blues(R) label).

         Gross sales to Sun's largest three customers decreased 41% in the
second quarter of 1996 versus sales in the same period of 1995, primarily as a
result of the soft retail environment. Gross sales to Sun's other customers
increased 12% in the second three months of 1996 versus the same period of 1995,
primarily as a result of the Company's concerted efforts to increase its private
label business.

         Sales deductions, consisting of sales returns, discounts and
allowances, decreased to $431,000 in the 1996 quarter from $607,000 in 1995.
This decrease was primarily due to decreases in the amount of product returns.

GROSS MARGIN. Gross margin as a percentage of net sales decreased to 15.8% in
the second quarter of 1996 from 17.2% in the second quarter of 1995. The
decrease primarily resulted from the fact that the reduced overall sales level
in 1996 had a disproportionate effect on gross margin (as a percentage of net
sales) due to the diminished capacity to cover the Company's fixed costs. The
above factor was partially offset by the Company's efforts to re-engineer its
operating processes, begun in 1995, which lowered Sun's manufacturing costs in
the second quarter of 1996, and the fact that customer returns were down in the
1996 quarter versus 1995. 

OPERATING EXPENSES. Operating expenses decreased to $3.0 million (or 14.9% of
net sales) in 1996 from $3.7 million (or 12.0% of net sales) in the second
quarter of 1995. The dollar decrease was primarily attributable to decreases in
selling, and general and administrative expenses. The increase as a percentage
of sales was the result of the lower sales volume in 1996, compared to the 1995
quarter.

         General and administrative expenses decreased to $1.5 million (or 7.6%
of net sales) in the second quarter of 1996 from $2.1 million (or 7.0% of net
sales) in the same period of 1995. The dollar decrease was primarily the result
of elimination of positions under a restructuring plan implemented by the
Company in the first quarter of 1996 (see "First Quarter 1996 Restructuring"
below). The increase as a percentage of sales was the result of the lower sales
volume in 1996, compared to the 1995 quarter.

         Selling expense decreased to $741,000 (or 3.7% of net sales) in the
second quarter of 1996 from $899,000 (or 2.9% of net sales) in the same period
of 1995. The dollar decrease was primarily the result of the elimination of
positions under a restructuring plan implemented by the Company in the first
quarter 

                                  Page 9 of 13

<PAGE>   10


of 1996 (see "First Quarter 1996 Restructuring" below). The increase as a
percentage of sales was the result of the lower sales volume in 1996, compared
to the 1995 quarter.

INTEREST EXPENSE. Quarterly interest expense decreased 51% to $176,000 in the
second quarter of 1996 from $361,000 in 1995 primarily as a result of lower
borrowing levels in the 1996 quarter.

NET INCOME. Net income decreased to $20,000 in the second quarter of 1996 from a
net income of $855,000 in the same period of 1995, as a result of the factors
described above.

FIRST QUARTER 1996 RESTRUCTURING. In February 1996, the Company initiated a
restructuring plan, that, among other things, resulted in the combining of Sun's
Women's and Girls' Division and Men's and Boys' Division. The restructuring plan
also resulted in the elimination of approximately 30 indirect positions from the
Company's workforce.

FIRST SIX MONTHS OF 1996 AND FIRST SIX MONTHS OF 1995

NET SALES. Net sales for the six months ended June 30, 1996 decreased 21% to
$44.5 million from $56.3 million in the same period of 1995. Gross sales of
women's and girls' apparel decreased 16% to $32.1 million in 1996 from $38.4
million in 1995. Sales of men's and boys' products decreased 31% to $13.4
million in the first six months of 1996 from $19.4 million in the same period of
1995. The Company believes the primary reason for these decreases was the soft
retail environment.

         Gross sales of licensed products decreased by 26% to $35.2 million in
the first half of 1996 from $47.3 million in the first half of 1995. The Company
believes the primary reason for this decrease was the soft retail environment.

         Gross sales of proprietary products remained virtually unchanged at
$10.3 million in the first six months of 1996 versus $10.4 million in the first
six months of 1995. The Company believes that sales of proprietary products held
relatively firm primarily as a result of the Company's concerted effort to
increase its private label business.

         Gross sales to Sun's largest three customers decreased 24% in the first
six months of 1996 versus the comparable period in 1995, primarily as a result
of the soft retail environment. Gross sales to Sun's other customers remained
virtually unchanged in the first half 1996 versus the first half of 1995,
primarily as a result of the Company's concerted efforts to increase its private
label business.

         Sales deductions, consisting of sales returns, discounts and
allowances, decreased to $1.1 million in 1996 from $1.5 million in the first
half of 1995. This decrease was primarily due to decreases in the amount of
product returns in the first half of 1996. 

GROSS MARGIN. Gross margin as a percentage of net sales increased to 15.7% in
the first half of 1996 from 15.0% in 1995. This increase was primarily the
result of three factors. First, customer returns were down in the first half of
1996 versus the first half of 1995. Second, 1995 margins were negatively
impacted by efforts to reduce men's inventory, including customer incentives and
substitution of existing, higher value inventory to fill customer orders for
lower value product, while the first six months of 1996 were not impacted by
such actions. Third, the Company's efforts to re-engineer its operating
processes, begun in 1995, lowered Sun's manufacturing costs in the first half of
1996. The above factors were partially offset by the reduced overall sales level
in 1996 which had a negative effect on gross margin (as a percentage of net
sales) due to the diminished capacity to cover the Company's fixed costs. 

OPERATING EXPENSES. Operating expenses decreased to $6.2 million (or 13.9% of
net sales) in 1996 from $7.3 million (or 12.9% of net sales) in the first half
of 1995. The dollar decrease was primarily attributable to decreases in selling,
and general and administrative expenses. The increase as a percentage of sales
is a result of the lower sales volume in 1996, compared to 1995.

         General and administrative expenses decreased to $3.2 million (or 7.3%
of net sales) in 1996 from $4.1 million (or 7.3% of net sales) in 1995. This
dollar decrease was primarily the result of elimination of positions under a
restructuring plan implemented by the Company in the first quarter of 1996 (see
"First Quarter 1996 Restructuring" above).


                                 Page 10 of 13

<PAGE>   11

         Selling expense decreased to $1.5 million (or 3.4% of net sales) in the
first half of 1996 from $1.9 million (or 3.4% of net sales) in the same period
of 1995. The dollar decrease was primarily the result of elimination of
positions under a restructuring plan implemented by the Company in the first
quarter of 1996 (see "First Quarter 1996 Restructuring" above).

INTEREST EXPENSE. Interest expense decreased 41% to $417,000 in the first half
of 1996 from $705,000 in 1995 primarily as a result of lower borrowing levels in
the 1996 half.

NET INCOME. Net income decreased to $287,000 in the first half of 1996 from
$354,000 in the same period of 1995, as a result of the factors described above.

QUARTERLY NET SALES - SEASONALITY

         The Company's net sales fluctuate from quarter to quarter. Quarterly
net sales for 1996 and 1995 are set forth below.

<TABLE>
<CAPTION>
                                     1996                     1995
                             ----------------------- -------------------------------
                                Amount    Percent        Amount    Percent
<S>                          <C>          <C>         <C>          <C> 
       First Quarter         $  24,433        *       $  25,720       27.4%
       Second Quarter           20,035        *          30,582       32.5
       Third Quarter                                     16,225       17.3
       Fourth Quarter                                    21,438       22.8
                             ---------    --------    ---------       ----

            Total            $  44,468                $  93,965      100.0%
                             =========                =========      =====
                                          * Unknown
</TABLE>


         The Company's highest sales and heaviest production demands
historically occur in the first, second and fourth quarters of each year. During
the first, second and fourth quarters, spring and summer products - which
include T-shirts, tank tops, shorts and similar garments - and back-to-school
products are primarily produced and sold. During the third and part of the
fourth quarter, winter season products - which include sweatshirts and long
sleeve T-shirts - and holiday products are primarily produced and sold.

LIQUIDITY AND CAPITAL RESOURCES

         The Company finances working capital needs primarily from "internally
generated funds" (which the Company defines as net income plus depreciation) and
short term borrowing under a credit agreement. In February 1996, the Company
entered into a credit agreement with Heller Financial, Inc. The Heller credit
agreement provides for a line of credit (including commercial letters of credit)
of up to $24 million and expires in February 1998. At June 30, 1996,
approximately $11.7 million was available for borrowing. The borrowing rate for
the revolving portion of the line is the prime rate. All the Company's assets,
including accounts receivable and inventories, are pledged as security for
borrowings under the Heller credit agreement. Under the agreement, the amount
borrowed at any time, together with letters of credit issued on behalf of the
Company, may not exceed 85% of eligible accounts receivable and 60% of eligible
inventory - up to $8.5 million. The Heller credit agreement requires compliance
with certain financial covenants principally relating to working capital,
tangible net worth, ratio of debt to equity, expenditures for fixed assets,
minimum earnings (before taxes, interest and depreciation), restrictions on the
payment of dividends and restrictions on the incurrence of long-term debt. The
Company was in compliance with the Heller debt covenants at June 30, 1996.

         Inventory levels decreased by $4.9 million or 21% from December 31,
1995 to June 30, 1996 primarily as a result of the Company's concerted efforts
to operate its business with lower levels of inventory. The Company believes
there was approximately $2.8 million (net of inventory markdown reserves of $3.1
million) of impaired surplus inventory on hand at June 30, 1996, which is
expected to be sold at little or no margin throughout 1996. As a result, the
Company believes its gross margin will be negatively impacted in the last half
of 1996 by 1% to 2% of net sales. 


                                 Page 11 of 13

<PAGE>   12


         Accounts receivable increased by 23% to $16.1 million at June 30, 1996
from $13.1 million at December 31, 1995 as a result of a temporary problem with
a customer's automated payment system (the problem was rectified shortly after
June 30, 1996).

         The Company has an agreement with Heller Financial, Inc., that is
intended to transfer the collection risk to Heller, for Sun's accounts
receivable for essentially all of its customers other than Target and Wal-Mart.
Under the agreement, Heller assumes 100% of the collection risk associated with
the Company's covered receivables and Heller receives a fee equal to .65% of the
gross amount of Kmart receivables and .55% of the gross amount of all other
covered receivables for assuming such collection risk. The agreement was amended
in the third quarter of 1996 to provide that Heller assumes 100% of the
collection risk associated with Kmart.

         Notes payable (borrowings under the Company's line of credit) decreased
$6.2 million or 46% from December 31, 1995 to June 30, 1996. The decrease in
notes payable was primarily the result of the reduction in inventory that
occurred during the first half of 1996.

         During the first half of 1996, the Company purchased approximately
$360,000 of machinery and equipment for production, warehouse, distribution and
office use. The Company anticipates that total expenditures for machinery and
equipment will be less than $200,000 during the remainder of 1996.

         Sun's primary ongoing cash needs are for working capital and capital
expenditures. The Company believes that its cash needs through the remainder of
1996 will be met by borrowings under its Heller credit facility.

INFLATION

         From time to time, Sun's suppliers of blank garments and materials
increase their prices. Further, Sun increases its employees' compensation
relative to increases in the cost of living. Sun's mass merchant customers have
historically sold Sun's more basic products at predetermined sales price points,
many of which have not risen during the last few years. Because Sun's customers
generally operate on a fixed markup, their strategy of not increasing their
sales price points has made it difficult for the Company to pass on any cost
increases relative to its more basic products.


PART II. OTHER INFORMATION

ITEM 1 - LEGAL PROCEEDINGS 
     No material change.

ITEM 2 - CHANGES IN SECURITIES
     None

ITEM 3 - DEFAULTS UPON SENIOR SECURITIES
     None

ITEM 4 - SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS
     None

ITEM 5 - OTHER INFORMATION
     None

ITEM 6 - EXHIBITS AND REPORTS ON FORM 8-K
     None



                                 Page 12 of 13
<PAGE>   13
                                   SIGNATURES


Pursuant to the requirements of the Securities and Exchange Act of 1934, the
Registrant has duly caused this report to be signed on its behalf by the
undersigned thereunto duly authorized.



                                         SUN SPORTSWEAR, INC.


DATE:  August 9, 1996              BY:  /s/ William S. Wiley
                                        ----------------------------------------
                                        William S. Wiley
                                        Chairman of the Board,
                                        Chief Executive Officer
                                        and President



DATE:  August 9, 1996              BY:  /s/ Kevin C. James
                                        ----------------------------------------
                                        Kevin C. James
                                        Senior Vice President
                                        and Chief Financial Officer



                                 Page 13 of 13



<TABLE> <S> <C>

<ARTICLE> 5
<LEGEND>
THIS SCHEDULE CONTAINS SUMMARY FINANCIAL INFORMATION EXTRACTED FROM FORM 10-Q
FOR THE QUARTER ENDED JUNE 30, 1996 AND IS QUALIFIED IN ITS ENTIRETY BY
REFERENCE TO SUCH FINANCIAL STATEMENTS.
</LEGEND>
<CIK> 0000856711
<NAME> SUN SPORTSWEAR, INC.
<MULTIPLIER> 1
<CURRENCY> U.S. DOLLARS
       
<S>                             <C>
<PERIOD-TYPE>                   6-MOS
<FISCAL-YEAR-END>                          DEC-31-1995
<PERIOD-START>                             JAN-01-1996
<PERIOD-END>                               JUN-30-1996
<EXCHANGE-RATE>                                      1
<CASH>                                         111,094
<SECURITIES>                                         0
<RECEIVABLES>                               16,179,330
<ALLOWANCES>                                    45,904
<INVENTORY>                                 18,766,448
<CURRENT-ASSETS>                            37,100,951
<PP&E>                                      10,852,879
<DEPRECIATION>                               6,468,757
<TOTAL-ASSETS>                              41,499,573
<CURRENT-LIABILITIES>                       15,038,515
<BONDS>                                        155,642
                                0
                                          0
<COMMON>                                    21,618,339
<OTHER-SE>                                           0
<TOTAL-LIABILITY-AND-EQUITY>                26,305,416
<SALES>                                     44,468,005
<TOTAL-REVENUES>                            44,468,005
<CGS>                                       37,495,432
<TOTAL-COSTS>                               43,661,482
<OTHER-EXPENSES>                              (44,856)
<LOSS-PROVISION>                                78,484
<INTEREST-EXPENSE>                             417,381
<INCOME-PRETAX>                                433,998
<INCOME-TAX>                                   147,000
<INCOME-CONTINUING>                            286,998
<DISCONTINUED>                                       0
<EXTRAORDINARY>                                      0
<CHANGES>                                            0
<NET-INCOME>                                   286,998
<EPS-PRIMARY>                                      .05
<EPS-DILUTED>                                      .05
        

</TABLE>


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