10-K 1 a38747.htm HONEYWELL INTERNATIONAL INC.



UNITED STATES
SECURITIES AND EXCHANGE COMMISSION
WASHINGTON, D.C. 20549

Form 10-K

S ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d)
OF THE SECURITIES EXCHANGE ACT OF 1934

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

For the transition period from        to       

Commission file number 1-8974

Honeywell International Inc.
(Exact name of registrant as specified in its charter)

DELAWARE

                                 22-2640650


                                

(State or other jurisdiction of

                                 (I.R.S. Employer

incorporation or organization)

                                 Identification No.)

101 Columbia Road
Morris Township, New Jersey

                                 07962


                                

(Address of principal executive offices)

                                 (Zip Code)

Registrant's telephone number, including area code (973)455-2000
Securities registered pursuant to Section 12(b) of the Act:

                                 Name of Each Exchange

Title of Each Class

                                 on Which Registered


                                

Common Stock, par value $1 per share*

                                 New York Stock Exchange

                                       Chicago Stock Exchange      

                                       Pacific Exchange      

Zero Coupon Serial Bonds due 2009

                                 New York Stock Exchange

912% Debentures due June 1, 2016

                                 New York Stock Exchange


* The common stock is also listed for trading on the London stock exchange.

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 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. S

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 nonaffiliates of the Registrant was approximately $31.5 billion at June 30, 2004.

There were 850,772,327 shares of Common Stock outstanding at January 31, 2005.

Documents Incorporated by Reference

Part III: Proxy Statement for Annual Meeting of Shareowners to be held April 25, 2005.




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TABLE OF CONTENTS

       Item

      Page

               

Part I.

    1.    Business        1  

     2.      Properties        11  

     3.      Legal Proceedings        12  

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

   Executive Officers of the Registrant        12  

Part II.

    5.    Market for Registrant's Common Equity, Related Stockholder Matters and Issuer
Purchases of Equity Securities
       14  

     6.      Selected Financial Data        15  

     7.      Management's Discussion and Analysis of Financial Condition and Results of Operations        15  

     7A.      Quantitative and Qualitative Disclosures About Market Risk        42  

     8.      Financial Statements and Supplementary Data        42  

     9.      Changes in and Disagreements with Accountants on Accounting and Financial Disclosure        92  

     9A.      Controls and Procedures        92  

     9B.      Other Information        93  

Part III.

    10.    Directors and Executive Officers of the Registrant        93  

     11.      Executive Compensation        93  

     12.      Security Ownership of Certain Beneficial Owners and Management        93  

     13.      Certain Relationships and Related Transactions        96  

     14.      Principal Accounting Fees and Services        96  

Part IV.

    15.    Exhibits and Financial Statement Schedules        96  

               


Signatures

               97  


      This report contains certain statements that may be deemed “forward-looking statements” within the meaning of Section 21E of the Securities Exchange Act of 1934. All statements, other than statements of historical fact, that address activities, events or developments that we or our management intends, expects, projects, believes or anticipates will or may occur in the future are forward-looking statements. Such statements are based upon certain assumptions and assessments made by our management in light of their experience and their perception of historical trends, current conditions, expected future developments and other factors they believe to be appropriate. The forward-looking statements included in this report are also subject to a number of material risks and uncertainties, including but not limited to economic, competitive, governmental and technological factors affecting our operations, markets, products, services and prices. Such forward-looking statements are not guarantees of future performance, and actual results, developments and business decisions may differ from those envisaged by such forward-looking statements.


PART I.

Item 1. Business

      Honeywell International Inc. (Honeywell) is a diversified technology and manufacturing company, serving customers worldwide with aerospace products and services, control, sensing and security technologies for buildings, homes and industry, turbochargers, automotive products, specialty chemicals, fibers, and electronic and advanced materials. Honeywell was incorporated in Delaware in 1985.

      We maintain an internet website at http://www.honeywell.com. Our Annual Report on Form 10-K, Quarterly Reports on Form 10-Q, Current Reports on Form 8-K, and any amendments to those reports, are available free of charge on our website under the heading “Investor Relations” (see “SEC Filings and Reports”) immediately after they are filed with, or furnished to, the Securities and Exchange Commission (SEC). Honeywell's Code of Business Conduct, Corporate Governance Guidelines and Charters of the Committees of the Board of Directors are also available, free of charge, on our website under the heading “Investor Relations” (see “Corporate Governance”), or by writing to Honeywell, 101 Columbia Road, Morris Township, New Jersey 07962, c/o Vice President and Corporate Secretary. Honeywell's Code of Business Conduct applies to all Honeywell directors, officers (including the Chief Executive Officer, Chief Financial Officer and Controller) and employees.

      The certifications of our Chief Executive Officer and Chief Financial Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002 about the disclosure contained in this Annual Report on Form 10-K are included as Exhibits 31.1 and 31.2 to this Annual Report and are available free of charge on our website under the heading “Investor Relations” (see “SEC Filings and Reports”). Our Chief Executive Officer certified to the New York Stock Exchange (NYSE) on May 20, 2004, pursuant to Section 303A.12 of the NYSE's listing standards, that he was not aware of any violation by Honeywell of the NYSE's corporate governance listing standards as of that date.

Major Businesses

      We globally manage our business operations through strategic business units, which have been aggregated under four reportable segments: Aerospace, Automation and Control Solutions, Specialty Materials and Transportation Systems. Financial information related to our reportable segments is included in Note 23 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data.”

      Following is further information about our four reportable segments which are comprised of various strategic business units and product classes that serve multiple end markets:

Strategic
Business Units

Product Classes

  Major Products/Services

  Major Customers/Uses

  Key Competitors

Aerospace

               

Engines, Systems and Services

Turbine propulsion
engines
  TFE731 turbofan
TPE331 turboprop
TFE1042 turbofan
ATF3 turbofan
F124 turbofan
LF502 turbofan
LF507 turbofan
CFE738 turbofan
HTF 7000 turbofan
T53, T55 turboshaft
LTS101 turboshaft
T800 turboshaft
AGT1500 turboshaft
Repair, overhaul and spare parts
  Business, regional,
general aviation and military trainer aircraft

Commercial and military
helicopters

Military vehicles
  United Technologies
(Pratt & Whitney Canada)

Rolls Royce/
Allison

Turbomeca
Williams
   

Auxiliary power units
(APUs)
  Airborne auxiliary
power units

Jet fuel starters
Secondary power
systems

Ground power units
Repair, overhaul and spare parts
  Commercial, regional,
business and
military aircraft

Ground power
  United Technologies
(Pratt & Whitney
Canada)

United Technologies
(Hamilton Sundstrand)
   

1


Strategic
Business Units

Product Classes

  Major Products/Services

  Major Customers/Uses

  Key Competitors

  Environmental control
systems
  Air management systems:
   Air conditioning
   Bleed air
   Cabin pressure control
   Air purification and treatment
Electrical power systems:
   Power distribution and control
   Emergency power generation
   Repair, overhaul and spare parts
  Commercial, regional
and general
aviation aircraft

Military aircraft
Ground vehicles
Spacecraft
  Auxilec
Barber Colman
Dukes
Eaton-Vickers
Goodrich (Lucas Aerospace)
Liebherr
Litton Breathing Systems
Pacific Scientific
Parker Hannifin
United Technologies
(Hamilton
Sundstrand)

Smiths
TAT
   

Engine systems and
accessories
  Electronic and
hydromechanical
fuel controls

Engine start systems
Electronic engine controls
Sensors
Electric and pneumatic power generation systems
Thrust reverser actuation, pneumatic and electric
  Commercial, regional and general aviation aircraft
Military aircraft
  BAE Controls
Goodrich (Chandler-Evans)
Goodrich (Lucas Aerospace)
Parker Hannifin
United Technologies
(Hamilton Sundstrand)
   

Aircraft hardware distribution   Fasteners, including nuts, bolts, rivets, clamps and pins
Bearings, including ball, roller, spherical, needle and ceramic
Electrical hardware, including connectors, components, lighting products, terminals, and wire and wiring accessories
Seals, including seals, o-rings, gaskets and packings
Value-added services, repair and overhaul kitting and point-of-use replenishment
  Commercial, regional, business and military aviation aircraft   Anixter (Pentacon)
Arrow Pemco
Avnet
BE Aerospace (M&M Aerospace)
Fairchild Direct
Satair
Wencor

Wesco Aircraft

Aerospace
Electronic
Systems

Avionics systems   Flight safety systems:
   Enhanced Ground Proximity Warning
   Systems    (EGPWS)

   Traffic Alert and
   Collision Avoidance Systems (TCAS)

   Windshear detection systems
   Flight data and cockpit voice
   recorders

   Weather Radar
Communication, navigation and surveillance systems:
   Weather radar
   Navigation & communication radios
   Air-to-ground telephones

   Global positioning systems
   Automatic flight control systems
   Satellite systems
   Surveillance systems
Integrated systems
Flight management systems
  Commercial, business
and general aviation aircraft

Government aviation
  BAE
Boeing/Jeppesen
Garmin
Goodrich
Kaiser
L3
Lockheed Martin
Northrop Grumman
Rockwell Collins
Smiths
Thales
Trimble/Terra
Universal Avionics
Universal Weather

      Cockpit display systems        

2


Strategic
Business Units

Product Classes

  Major Products/Services

  Major Customers/Uses

  Key Competitors

      Data management and aircraft performance monitoring systems
Vehicle management systems
Aircraft information systems
       

      Network file servers
Wireless network transceivers
Satellite TV systems
Audio/Video equipment
Weather information network
Navigation database information
Cabin management systems
Vibration detection and monitoring
Mission management systems
Tactical data management systems
       
   

Aircraft, Obstruction and Airport lighting   Inset lights
Control and monitoring systems
Regulators
Tower and obstruction lights
Interior and exterior aircraft lighting
Visual docking guidance systems
  Airports
Commercial, regional, business, helicopter and military aviation aircraft (operators, OEMs, parts distributors and MRO service providers)
General contractors (building and tower manufacturers), cell phone companies
  Bruce
Hella/Goodrich
LSI
Luminator
Safegate
Siemens
Thorn
Whelen
   

Inertial sensor   Inertial sensor systems for guidance, stabilization, navigation and control
Gyroscopes, accelerometers, inertial measurement units and thermal switches
  Military and
commercial vehicles

Commercial spacecraft
and launch vehicles

Commercial, regional, business and military aircraft
Transportation
Missiles
Munitions
  Astronautics-
Kearfott

BAE
Ball
GEC
L3 Com
KVH
Northrop Grumman
Rockwell
Smiths
   

Automatic test
equipment
  EW ATE
Avionics ATE
Vehicle health
Management
  Boeing
USAF
Foreign air forces
  Northrop Grumman
Lockheed
   

Control products   Radar altimeters
Pressure products
Air data products
Thermal switches
Magnetic sensors
  Military aircraft
Missiles, UAVs
Commercial
applications
  Ball Brothers
BAE
Druck
Goodrich
NavCom
Northrop Grumman
Rosemount
Solarton
   

Space products and subsystems   Guidance subsystems
Control subsystems
Processing subsystems
Radiation hardened electronics and integrated circuits
GPS-based range safety systems
  Commercial and military-spacecraft
DoD
FAA
NASA
  BAE
Ithaco
L3
Northrop Grumman
Raytheon
   

3


Strategic
Business Units

Product Classes

  Major Products/Services

  Major Customers/Uses

  Key Competitors

  Management and technical services   Maintenance/operation and provision of space systems, services and facilities
Systems engineering and integration
Information technology services
Logistics and sustainment
  U.S. government space (NASA)
DoD (logistics and
information services)

DoE
Local governments
Commercial space ground segment systems and services
  Bechtel
Boeing
Computer Sciences
Dyncorp
ITT
Lockheed Martin
Raytheon
SAIC
The Washington Group
United Space Alliance

Aircraft Landing Systems Landing systems   Wheels and brakes
Friction products
Wheel and brake
repair and
overhaul services
  Commercial airline,
regional, business
and military aircraft

High performance commercial vehicles
USAF, DoD, DoE
Boeing, Airbus, Lockheed Martin
  Aircraft Braking
Systems

Dunlop Standard Aerospace
Goodrich
Messier-Bugatti
NASCO
Various smaller repair and overhaul companies


Automation and Control Solutions

               

Products

Environmental controls and combustion; sensing and controls   Heating, ventilating and air conditioning controls and components for homes and buildings
Indoor air quality products including zoning, air cleaners, humidification, heat and energy recovery ventilators
Controls plus integrated electronic systems for burners, boilers and furnaces
Consumer household products including humidifiers and thermostats
Water controls
Sensors, measurement, control and industrial components
  Original equipment manufacturers (OEMs)
Distributors
Contractors
Retailers
System integrators
Commercial customers and homeowners served by the distributor, wholesaler, contractor, retail and utility channels
Package and materials handling operations
Appliance manufacturers
Automotive companies
Aviation companies
Food and beverage processors
Medical equipment
Heat treat processors
Computer and business equipment manufacturers
  Bosch
Carrier
Cherry
Danfoss
Eaton
Emerson
Endruss & Hauser
Holmes
Invensys
Johnson Controls
Motorola
Omron
Schneider
Siemens
Yokogawa
   
  Security and life safety
products and services
  Security products and systems
Fire products and systems
Access controls and closed circuit television
Home health monitoring
  OEMs
Retailers
Distributors
Commercial customers
and homeowners served by the distributor, wholesaler, contractor, retail and utility channels

Health care organizations
  Bosch
GE
Pelco
Phillips
Siemens
SPX
Tyco

               

Process Solutions

Industrial automation
solutions
  Advanced control software and industrial automation systems for control and monitoring of continuous, batch and hybrid operations
Production management software
Communications systems for Industrial Control equipment and systems
Consulting, networking engineering and installation
Process control instrumentation
Field instrumentation
  Refining and petrochemical companies
Chemical manufacturers
Oil and gas producers
Food and beverage processors
Pharmaceutical companies
Utilities
Film and coated producers
Pulp and paper industry
Continuous web producers in the paper, plastics, metals, rubber, non-wovens and printing industries
Mining and mineral industries
  Asea Brown Boveri
Aspen Tech
Emerson
Invensys
Siemens
Yokogawa

4


Strategic
Business Units

Product Classes

  Major Products/Services

  Major Customers/Uses

  Key Competitors

        Analytical instrumentation
Recorders
Controllers
Critical environment control solutions and services
Aftermarket maintenance, repair and upgrade
       

Building Solutions Solutions and services   HVAC and building control solutions and services
Energy management solutions and services
Security and asset management solutions and services
Enterprise building integration solutions
Building information services
  Building managers and owners
Contractors, architects and developers
Consulting engineers
Security directors
Plant managers
Utilities
Large, global corporations
Public school systems
Universities
Local governments
  GroupMac
Invensys
Johnson Controls
Local contractors and utilities
Siemens
Trane


Specialty Materials

               

Specialty Materials

Nylon   Nylon filament and staple yarns
Nylon bulk
continuous filament

Nylon polymer
Caprolactam
Ammonium sulfate
Cyclohexanol
Cyclohexanone
Sulfuric acid
Ammonia
  Commercial, residential and specialty carpet markets
Nylon for fibers, engineered resins and film
Fertilizer ingredients
Specialty chemicals
  BASF
DSM
Enichem
Hoechst
Invista
Monsanto
Rhodia
Solutia
   

Advanced Fibers & Composites   High molecular weight polyethylene fiber and shield composites
Aramid shield composites
  Bullet resistant vests, helmets and other armor applications
Cut-resistant gloves
Rope & cordage
  DuPont
DSM
Teijin
   

Specialty Films   Cast nylon film
Bi-axially oriented nylon film
Fluoropolymer film
  Food and pharmaceutical packaging   American Biaxis
CFP
Daikan
Kolon
Unitika
   

Specialty additives   Polyethylene waxes
Petroleum waxes and blends
PVC lubricant systems
Plastic additives
Luminescent photodyes
  Coatings and inks
PVC
Plastics
Reflective coatings
Security and safe applications
  BASF
Clarient
Eastman
   

Fluorocarbons   Genetron® refrigerants, aerosol and
insulation foam blowing
agents

Genesolv® solvents
Oxyfume sterilant gases
Ennovate 3000 blowing agent for refrigeration insulation
  Refrigeration
Air conditioning
Polyurethane foam
Precision cleaning
Optical
Metalworking
Hospitals
Medical equipment
manufacturers
  Arkema
INEOS Fluor
Solvay-Solexis
   

Hydrofluoric acid (HF)   Anhydrous and aqueous hydrofluoric acid   Fluorocarbons
Steel
Oil refining
Chemical intermediates
  Ashland
Atofina
E. Merck
Hashimoto
Norfluor
Quimica Fluor
   

Fluorine specialties   Sulfur hexafluoride (SF6)
Iodine pentafluoride (IF5)
Antimony pentafluoride
(SbF
5)
  Electric utilities
Magnesium
Gear manufacturers
  Air Products
Asahi Glass
Atofina
Solvay-Solexis
   

5


Strategic
Business Units

Product Classes

  Major Products/Services

  Major Customers/Uses

  Key Competitors

Nuclear services   UF6 conversion services   Nuclear fuel
Electric utilities
  British Nuclear Fuels
Cameco
Cogema
   

Research and life sciences   Active pharmaceutical ingredients
Pharmaceutical intermediates
Pharmaceutical formulations
Oxime-based fine chemicals
Fluoroaromatics
Bromoaromatics
High-purity solvents
  Agrichemicals
Pharmaceuticals
Biotech
  Avecia
Degussa
DSM
E. Merck
Fisher Scientific
Lonza
Sigma-Aldrich
   

Performance chemicals
  Imaging chemicals
  Chemical processing
  Display chemicals
  Surface treatment
  Catalysts
  Sealants
  HF derivatives
Fluoroaromatics
Phosphors
Catalysts
Oxime-silanes
Hydroxylamine
  Diverse by product type   Atotech
BASF
Solvay-Solexis
   

Electronic chemicals   Ultra high-purity HF
Inorganic acids
Hi-purity solvents
  Semiconductors   Air Products
Arch
E. Merck
   

Semiconductor
materials and
services
  Interconnect-
dielectrics

Interconnect-metals
Semiconductor packaging materials
Advanced polymers
Sapphire substrates
Anti-reflective coatings
Thermo-couplings
  Semiconductors
Microelectronics
Telecommunications
  ATMI
Dow Chemical
Dow Corning
Japan Energy
JSR
Sumitomo
Tokyo-Ohka
Tosoh SMD
   

UOP (50%-owned joint venture)   Catalysts
Molecular sieves
Adsorbents
Design of process,
plants and equipment

Customer catalyst manufacturing
  Petroleum,
petrochemical, gas
processing and
chemical industries
  ABB Lummus
Axens
Exxon-Mobil
Procatalyse
Shell/Criterion
Stone & Webster
Zeochem


Transportation Systems

               
Honeywell Turbo Technologies Charge-air systems   Turbochargers
Remanufactured components
  Passenger car, truck
and off-highway
OEMs

Engine manufacturers
Aftermarket distributors and dealers
  ABB
Borg-Warner
Hitachi
Holset
IHI
MHI
Tianyan
   
  Thermal systems   Exhaust gas coolers
Charge-air coolers
Aluminum radiators
Aluminum cooling
modules
  Passenger car, truck
and off-highway OEMs

Engine manufacturers
Aftermarket distributors and dealers
  Behr/McCord
Modine
Valeo

6


Strategic
Business Units

Product Classes

  Major Products/Services

  Major Customers/Uses

  Key Competitors

Consumer Products Group Aftermarket
filters, spark plugs, electronic components and car care products
  Oil, air, fuel, transmission and coolant filters
PCV valves
Spark plugs
Wire and cable
Antifreeze/coolant
Ice-fighter products
Windshield washer fluids
Waxes, washes and specialty cleaners
  Automotive and heavy
vehicle aftermarket channels, OEMs and OES

Auto supply retailers
Specialty installers
Mass merchandisers
  AC Delco
Bosch
Champion
Champ Labs
Havoline/Texaco
Mann & Hummel
NGK
Peak/Old World
Industries

Pennzoil-Quaker
State

Purolator/Arvin Ind
STP/ArmorAll/
Clorox

Turtle Wax
Various Private Label
Wix/Dana
Zerex/Valvoline

Friction Materials

Friction materials
Aftermarket brake hard
parts
  Disc brake pads and shoes
Drum brake linings
Brake blocks
Disc and drum brake components
Brake hydraulic components
Brake fluid
Aircraft brake linings
Railway linings
  Automotive and heavy vehicle OEMs, OES, brake manufacturers and aftermarket channels
Mass merchandisers
Installers
Railway and commercial/
military aircraft OEMs
and brake manufacturers
  Akebono
Dana
Delphi
Federal-Mogul
ITT Galfer
JBI
Nisshinbo
TMD
Roulunds

Aerospace Sales

      Our sales to aerospace customers were 38, 38 and 40 percent of our total sales in 2004, 2003 and 2002, respectively. Our sales to commercial aerospace original equipment manufacturers were 8, 7 and 9 percent of our total sales in 2004, 2003 and 2002, respectively. If there are large changes in sales of aircraft that use our components, operating results could be impacted. In addition, our sales to commercial aftermarket customers of aerospace products and services were 16, 15 and 16 percent of our total sales in 2004, 2003, and 2002, respectively. If there are large changes in the number of global flying hours or landings for aircraft that use our components or services, operating results could be impacted. The terrorist attacks on September 11, 2001 resulted in an abrupt downturn in the aviation industry which was already negatively impacted by a weak economy. This dramatic downturn in the commercial air transport industry significantly impacted the operating results of our Aerospace segment in 2002 and 2003. We began to see some recovery at the end of 2003, which continued in 2004, aided by continued improvement in the commercial aerospace market segment and the favorable impact of safety mandates.

U.S. Government Sales

      Sales to the U.S. Government (principally by our Aerospace segment), acting through its various departments and agencies and through prime contractors, amounted to $3,464, $3,111 and $2,730 million in 2004, 2003 and 2002, respectively, which included sales to the U.S. Department of Defense, as a prime contractor and subcontractor, of $2,808, $2,564 and $2,046 million in 2004, 2003 and 2002, respectively. U.S. defense spending increased in 2004 and is also expected to increase in 2005.

      In addition to normal business risks, companies engaged in supplying military and other equipment to the U.S. Government are subject to unusual risks, including dependence on Congressional appropriations and administrative allotment of funds, changes in governmental procurement legislation and regulations and other policies that may reflect military and political developments, significant changes in contract scheduling, complexity of designs and the rapidity with which they become obsolete, necessity for constant design improvements, intense competition for U.S. Government business necessitating increases in time and investment for design and development, difficulty of forecasting costs and schedules when bidding on developmental and highly sophisticated technical work and other factors characteristic of the industry. Changes are customary over the life of U.S. Government contracts, particularly development contracts, and generally result in adjustments of contract prices.

7


      Our contracts with the U.S. Government are subject to audits. Like many other government contractors, we have received audit reports that recommend downward price adjustments to certain contracts to comply with various government regulations. We have made adjustments and paid voluntary refunds in appropriate cases. In addition, we accrue for liabilities associated with these government contract matters that are probable and can be reasonably estimated.

      U.S. Government contracts are subject to termination by the government, either for the convenience of the government or for our failure to perform under the applicable contract. In the case of a termination for convenience, we are typically entitled to reimbursement for our allowable costs incurred, plus termination costs and a reasonable profit. If a contract is terminated by the government for our failure to perform, we could be liable for additional costs incurred by the government in acquiring undelivered goods or services from another source and any other damages suffered by the government.

      We, like other government contractors, are subject to government investigations of business practices and compliance with government procurement regulations. If Honeywell or one of its businesses were charged with wrongdoing as a result of any such investigation or other government investigations (including violation of certain environmental or export laws), it could be suspended from bidding on or receiving awards of new government contracts pending the completion of legal proceedings. The U.S. Government also reserves the right to debar a contractor from receiving new government contracts for fraudulent, criminal or other egregious misconduct. Debarment generally does not exceed three years. Although the outcome of pending government investigations cannot be predicted with certainty, we are not aware of any investigations that we expect will have a material adverse effect on us.

Backlog

      Our total backlog at year-end 2004 and 2003 was $8,229 and $7,191 million, respectively. We anticipate that approximately $6,339 million of the 2004 backlog will be filled in 2005. We believe that backlog is not necessarily a reliable indicator of our future sales because a substantial portion of the orders constituting this backlog may be canceled at the customer's option.

Competition

      We are subject to active competition in substantially all product and service areas. Competition is expected to continue in all geographic regions. Competitive conditions vary widely among the thousands of products and services provided by us, and vary country by country. Depending on the particular customer or market involved, our businesses compete on a variety of factors, such as price, quality, reliability, delivery, customer service, performance, applied technology, product innovation and product recognition. Brand identity, service to customers and quality are generally important competitive factors for our products and services, and there is considerable price competition. Other competitive factors for certain products include breadth of product line, research and development efforts and technical and managerial capability. While our competitive position varies among our products and services, we believe we are a significant competitor in each of our major product and service classes. However, a number of our products and services are sold in competition with those of a large number of other companies, some of which have substantial financial resources and significant technological capabilities. In addition, some of our products compete with the captive component divisions of original equipment manufacturers.

International Operations

      We are engaged in manufacturing, sales, service and research and development mainly in the United States, Europe, Canada, Asia and Latin America. U.S. exports and foreign manufactured products are significant to our operations. U.S. exports comprised 9 and 10 percent of our total net sales in 2004 and 2003, respectively. Foreign manufactured products and services, mainly in Europe, were 35 and 34 percent of our total net sales in 2004 and 2003, respectively.

      Our international operations, including U.S. exports, are potentially subject to a number of unique risks and limitations, including: fluctuations in currency value; exchange control regulations; wage and price controls; employment regulations; foreign investment laws; import and trade restrictions, including embargoes; and governmental instability.

      Approximately 18 percent of total 2004 net sales of Aerospace-related products and services were exports of U.S. manufactured products and systems and performance of services such as aircraft

8


repair and overhaul. Exports were principally made to Europe, Asia and Canada. Foreign manufactured products and systems and performance of services comprised 14 percent of total 2004 Aerospace net sales.

      Approximately 3 percent of total 2004 net sales of Automation and Control Solutions products were exports of U.S. manufactured products. Foreign manufactured products and performance of services accounted for 49 percent of total 2004 net sales of Automation and Control Solutions. The principal manufacturing facilities outside the U.S. are in Europe and Mexico, with less significant operations in Asia and Canada.

      Approximately 11 percent of total 2004 net sales of Specialty Materials were exports of U.S. manufactured products. Exports were principally made to Asia, Europe, Latin America and Canada. Foreign manufactured products comprised 29 percent of total 2004 net sales of Specialty Materials. The principal manufacturing facilities outside the U.S. are in Europe, with less significant operations in Asia and Canada.

      Exports of U.S. manufactured products comprised 1 percent of total 2004 net sales of Transportation Systems products. Foreign manufactured products accounted for 62 percent of total 2004 net sales of Transportation Systems. The principal manufacturing facilities outside the U.S. are in Europe, with less significant operations in Asia, Latin America and Canada.

Raw Materials

      The principal raw materials used in our operations are generally readily available. We experienced no significant or unusual problems in the purchase of key raw materials and commodities in 2004. We are not dependent on any one supplier for a material amount of our raw materials. However, we are highly dependent on our suppliers and subcontractors in order to meet commitments to our customers. In addition, many major components and product equipment items are procured or subcontracted on a sole-source basis with a number of domestic and foreign companies. We maintain a qualification and performance surveillance process to control risk associated with such reliance on third parties. While we believe that sources of supply for raw materials and components are generally adequate, it is difficult to predict what effects shortages or price increases may have in the future. The costs of certain key raw materials, including natural gas and benzene, in our Specialty Materials' business were at historically high levels in 2004 and are expected to remain at those levels in 2005. We will continue to attempt to offset raw material cost increases with price increases where feasible. At present, we have no reason to believe a shortage of raw materials will cause any material adverse impact during 2005.

Patents, Trademarks, Licenses and Distribution Rights

      Our business as a whole, and that of our strategic business units, are not dependent upon any single patent or related group of patents, or any licenses or distribution rights. We own, or are licensed under, a large number of patents, patent applications and trademarks acquired over a period of many years, which relate to many of our products or improvements to those products and which are of importance to our business. From time to time, new patents and trademarks are obtained, and patent and trademark licenses and rights are acquired from others. We also have distribution rights of varying terms for a number of products and services produced by other companies. In our judgment, those rights are adequate for the conduct of our business. We believe that, in the aggregate, the rights under our patents, trademarks and licenses are generally important to our operations, but we do not consider any patent, trademark or related group of patents, or any licensing or distribution rights related to a specific process or product, to be of material importance in relation to our total business.

      We have registered trademarks for a number of our products, including such consumer brands as Honeywell, Prestone, FRAM, Anso, Autolite, Bendix, Jurid and Garrett.

Research and Development

      Our research activities are directed toward the discovery and development of new products and processes and the development of new uses for existing products.

      Research and development expense totaled $917, $751 and $757 million in 2004, 2003 and 2002, respectively. The increase in research and development expense in 2004 compared with 2003 results primarily from design and developments costs associated with new aircraft platforms in Aerospace and new product development costs in Automation and Control Solutions. Customer-sponsored (principally the U.S. Government) research and development activities amounted to an additional $593, $608 and $603 million in 2004, 2003 and 2002, respectively.

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Environment

      We are subject to various federal, state, local and foreign government requirements regulating the discharge of materials into the environment or otherwise relating to the protection of the environment. It is our policy to comply with these requirements, and we believe that, as a general matter, our policies, practices and procedures are properly designed to prevent unreasonable risk of environmental damage, and of resulting financial liability, in connection with our business. Some risk of environmental damage is, however, inherent in some of our operations and products, as it is with other companies engaged in similar businesses.

      We are and have been engaged in the handling, manufacture, use and disposal of many substances classified as hazardous or toxic by one or more regulatory agencies. We believe that, as a general matter, our policies, practices and procedures are properly designed to prevent unreasonable risk of environmental damage and personal injury, and that our handling, manufacture, use and disposal of these substances are in accord with environmental and safety laws and regulations. It is possible, however, that future knowledge or other developments, such as improved capability to detect substances in the environment or increasingly strict environmental laws and standards and enforcement policies, could bring into question our current or past handling, manufacture, use or disposal of these substances.

      Among other environmental requirements, we are subject to the federal superfund and similar state and foreign laws and regulations, under which we have been designated as a potentially responsible party that may be liable for cleanup costs associated with various hazardous waste sites, some of which are on the U.S. Environmental Protection Agency's superfund priority list. Although, under some court interpretations of these laws, there is a possibility that a responsible party might have to bear more than its proportional share of the cleanup costs if it is unable to obtain appropriate contribution from other responsible parties, we have not had to bear significantly more than our proportional share in multi-party situations taken as a whole.

      In the matter entitled Interfaith Community Organization, et al. v. Honeywell International Inc., et al., the United States District Court for the District of New Jersey held in May 2003 that a predecessor Honeywell site located in Jersey City, New Jersey constituted an imminent and substantial endangerment and ordered Honeywell to conduct the excavation and transport for offsite disposal of approximately one million tons of chromium residue present at the site. Honeywell appealed the Court's decision to the Third Circuit Court of Appeals (Appeals Court). As disclosed in prior SEC filings, we believed that the District Court-ordered remedy would be remanded, reversed or replaced and, accordingly, provisions previously made in our financial statements for remedial costs at this site did not assume excavation and offsite removal of chromium. On February 18, 2005, the Appeals Court denied Honeywell's appeal. In light of the Appeals Court decision, we recorded a pre-tax charge of $278 million in the fourth quarter of 2004, which reflects the incremental cost of implementing the Court-ordered remedy. Implementation of the excavation and offsite removal remedy is expected to take place over a five-year period, and the cost of implementation is expected to be incurred evenly over that period. We do not expect implementation of the remedy to have a material adverse effect on our future consolidated results of operations, operating cash flows or financial position.

      In accordance with a 1992 consent decree with the State of New York, Honeywell is studying environmental conditions in and around Onondaga Lake (the Lake) in Syracuse, New York. The purpose of the study is to identify, evaluate and propose remedial measures that can be taken to remedy historic industrial contamination in the Lake. A predecessor company to Honeywell operated a chemical plant which is alleged to have contributed mercury and other contaminants to the Lake. In November 2004, the New York State Department of Environmental Conservation (the DEC) issued its Proposed Plan for remediation of industrial contamination in the Lake. There will be a public comment period until March 1, 2005, and the Proposed Plan is subject to review by the U.S. Environmental Protection Agency. The DEC is currently expected to issue its Record of Decision in the first half of 2005.

      The Proposed Plan calls for a combined dredging/capping remedy generally in line with the approach recommended in the Feasibility Study submitted by Honeywell in May 2004 (the May 2004 Feasibility Study). Although the Proposed Plan calls for additional remediation in certain parts of the Lake, it would not require the most extensive dredging alternatives described in the May 2004 Feasibility Study. The DEC's aggregate cost estimate is based on the high end of the range of potential costs for major elements of the Proposed Plan and includes a contingency. The actual cost of the

10


Proposed Plan will depend upon, among other things, the resolution of certain technical issues during the design phase of the remediation, expected to occur sometime in 2007 and beyond.

      Based on currently available information and analysis performed by our engineering consultants, our estimated cost of implementing the remedy set forth in the Proposed Plan is consistent with amounts previously provided for in our financial statements. Our estimating process considered a range of possible outcomes and amounts recorded reflect our best estimate at this time. We do not believe that this matter will have a material adverse impact on our consolidated financial position. Given the scope and complexity of this project, it is possible that actual costs could exceed estimated costs by an amount that could have a material adverse impact on our consolidated results of operations and operating cash flows in the periods recognized or paid. At this time, however, we cannot identify any legal, regulatory or technical reason to conclude that a specific alternative outcome is more probable than the outcome for which we have made provisions in our financial statements.

      Further information regarding environmental matters is included in “Item 7. Management's Discussion and Analysis of Financial Condition and Results of Operations.”

Employees

      We have approximately 109,000 employees at December 31, 2004, of which approximately 60,000 were located in the United States.

Item 2.    Properties

      We have 1,152 locations consisting of plants, research laboratories, sales offices and other facilities. Our headquarters and administrative complex is located at Morris Township, New Jersey. Our plants are generally located to serve large marketing areas and to provide accessibility to raw materials and labor pools. Our properties are generally maintained in good operating condition. Utilization of these plants may vary with sales to customers and other business conditions; however, no major operating facility is significantly idle. We own or lease warehouses, railroad cars, barges, automobiles, trucks, airplanes and materials handling and data processing equipment. We also lease space for administrative and sales staffs. Our properties and equipment are in good operating condition and are adequate for our present needs. We do not anticipate difficulty in renewing existing leases as they expire or in finding alternative facilities.

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      Our principal plants, which are owned in fee unless otherwise indicated, are as follows:

         Aerospace    
   Glendale, AZ (partially leased)
Phoenix, AZ
Tempe, AZ
Tucson, AZ
Torrance, CA (partially leased)
Clearwater, FL
     South Bend, IN
Olathe, KS
Minneapolis, MN
Plymouth, MN
Teterboro, NJ
      Rocky Mount, NC
Urbana, OH
Redmond, WA (leased)
Toronto, Canada
Raunheim, Germany
         Automation and Control Solutions    
   Phoenix, AZ
San Diego, CA
     Northford, CT
Freeport, IL
Golden Valley, MN
      Chihuahua, Mexico
Juarez, Mexico
Newhouse, Scotland
         Specialty Materials    
   Baton Rouge, LA
Geismar, LA
     Pottsville, PA
Chesterfield, VA
      Hopewell, VA
Seelze, Germany
         Transportation Systems    
   Mexicali, Mexico      Thaon-Les-Vosges, France
Glinde, Germany
      Atessa, Italy

Item 3.    Legal Proceedings

      We are subject to a number of lawsuits, investigations and claims (some of which involve substantial amounts) arising out of the conduct of our business. See a discussion of environmental, asbestos and other litigation matters in Note 21 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data.”

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

      Not Applicable.

Executive Officers of the Registrant

      The executive officers of Honeywell, listed as follows, are elected annually by the Board of Directors. There are no family relationships among them.

Name, Age,
Date  First
Elected an
Executive Officer
                                              Business Experience                                   
          

David M. Cote (a), 52
      2002      

           Chairman of the Board and Chief Executive Officer since July 2002. President and Chief Executive Officer from February 2002 to June 2002. Chairman of the Board, President and Chief Executive Officer of TRW (manufacturer of aerospace and automotive products) from August 2001 to February 2002. President and Chief Executive Officer of TRW from February 2001 to July 2001. President and Chief Operating Officer of TRW from November 1999 to January 2001. Senior Vice President of General Electric Company and President and Chief Executive Officer of GE Appliances from June 1996 to November 1999.

Adriane M. Brown, 46
      2005      

           President and Chief Executive Officer Transportation Systems since January 2005. Vice President and General Manager of Engine Systems & Accessories from September 2001 to December 2004. Vice President and General Manager of Aircraft Landing Systems from October 1999 to August 2001.


(a) Also a Director.

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Name, Age,
Date  First
Elected an
Executive Officer
                                              Business Experience                                   
          

Dr. Nance K. Dicciani, 57
      2001      

           President and Chief Executive Officer Specialty Materials since November 2001. Senior Vice President and Business Group Executive of Chemical Specialties and Director, European Region of Rohm and Haas (chemical company) from June 1998 to October 2001.

Roger Fradin, 51
      2004      

           President and Chief Executive Officer Automation and Control Solutions since January 2004. President of Automation and Control Products from June 2002 to December 2003. President and Chief Executive Officer of Security and Fire Solutions from February 2000 to May 2002. President of The Security Group of The Pittway Corporation from September 1995 to April 2002.

Robert J. Gillette, 44
      2001      

           President and Chief Executive Officer Aerospace since January 2005. President and Chief Executive Officer Transportation Systems from July 2001 to December 2004. President of Honeywell Turbo Technologies from July 2000 to June 2001. Vice President and General Manager of Engineering Plastics from December 1996 to June 2000.

   

David J. Anderson, 55
      2003      

           Senior Vice President and Chief Financial Officer since June 2003. Senior Vice President and Chief Financial Officer of ITT Industries (global manufacturing company) from December 1999 to June 2003.

Larry E. Kittelberger, 56
      2001      

           Senior Vice President Administration and Chief Information Officer since August 2001. Senior Vice President and Chief Information Officer of Lucent Technologies Inc. from November 1999 to August 2001.

Peter M. Kreindler, 59
      1992      

           Senior Vice President and General Counsel since March 1992. Secretary from December 1994 through November 1999.

Thomas W. Weidenkopf, 46
      2002      

           Senior Vice President Human Resources and Communications since April 2002. Vice President of Human Resources, Aerospace, from March 1999 to March 2002.

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Part II.

Item 5.    Market for Registrant's Common Equity, Related Stockholder
                 Matters and Issuer Purchases of Equity Securities

      Market and dividend information for Honeywell's common stock is included in Note 26 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data.”

      The number of record holders of our common stock at December 31, 2004 was 83,995.

      The following table summarizes Honeywell's purchases of its common stock, par value $1 per share, for the quarter ending December 31, 2004:

Issuer Purchases of Equity Securities

      (a)   (b)   (c)   (d)
       Period

  Total
Number of
Shares
Purchased

  Average
Price Paid
per Share

  Total
Number of
Shares
Purchased as
Part of Publicly
Announced
Plans or
Programs

  Maximum
Number (or
Approximate
Dollar Value) of
Shares that
May Yet be
Purchased Under
Plans or
Programs

      

October 2004

       4,250,000               $ 33.32                 4,250,000                 (A)  
      

November 2004

       6,750,000               $ 35.61                 6,750,000                 (A)  
      

December 2004

                                                       (A)  
      

                               

(A)   In November 2003, Honeywell announced its intention to repurchase sufficient outstanding shares of its common stock to offset the dilutive impact of employee stock based compensation plans, including future option exercises, restricted unit vesting and matching contributions under our savings plans. We estimate the issuance of approximately 10 million shares annually under such plans. Total repurchases may vary depending on market conditions and the level of other investing activities. In response to market conditions, in the fourth quarter of 2004, we repurchased shares to offset the anticipated 2005 dilutive impact of employee stock based compensation plans, bringing the total number of shares repurchased in 2004 to 20,072,650. Accordingly, we do not anticipate the need for additional share repurchases in 2005 under this program.

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Item 6.    Selected Financial Data

    Years Ended December 31,

    2004

  2003

  2002

  2001

  2000

  1999

    (Dollars in millions, except per share amounts)

Results of Operations

                                               

Net sales

     $ 25,601        $ 23,103        $ 22,274        $ 23,652        $ 25,023        $ 23,735  

Net income (loss)(1)

       1,281          1,324          (220 )        (99 )        1,659          1,541  

Per Common Share

                                               

Net earnings (loss):

                                               

Basic

       1.49          1.54          (0.27 )        (0.12 )        2.07          1.95  

Assuming dilution

       1.49          1.54          (0.27 )        (0.12 )        2.05          1.90  

Dividends

       0.75          0.75          0.75          0.75          0.75          0.68  

Financial Position at Year-End

                                               

Property, plant and equipment—net

       4,331          4,295          4,055          4,933          5,230          5,630  

Total assets

       31,062          29,314          27,565          24,226          25,175          23,527  

Short-term debt

       1,204          199          370          539          1,682          2,609  

Long-term debt

       4,069          4,961          4,719          4,731          3,941          2,457  

Total debt

       5,273          5,160          5,089          5,270          5,623          5,066  

Shareowners' equity

       11,252          10,729          8,925          9,170          9,707          8,599  

                                               


Note: Commencing January 1, 2002, we ceased amortization of goodwill and indefinite-lived intangible assets.

(1)   In 2004, includes net repositioning, environmental, litigation, business impairment and other charges, gains on sales of non-strategic businesses and a gain related to the settlement of a patent infringement lawsuit resulting in a net after-tax charge of $315 million, or $0.36 per share. In 2003, includes the cumulative after-tax charge of $20 million, or $0.02 per share, for the adoption of SFAS No. 143. In 2003, also includes net repositioning, environmental and other charges, gains on sales of non-strategic businesses and a gain related to the settlement of a patent infringement lawsuit resulting in a net after-tax charge of $22 million, or $0.03 per share. In 2002, includes net repositioning, litigation, business impairment and other charges and gains on sales of non-strategic businesses resulting in a net after-tax charge of $1,864 million, or $2.27 per share. In 2001, includes net repositioning, litigation, business impairment and other charges resulting in an after-tax charge of $1,771 million, or $2.18 per share. In 2000, includes net repositioning, litigation, business impairment and other charges and a gain on the sale of the TCAS product line of Honeywell Inc. resulting in a net after-tax charge of $634 million, or $0.78 per share. In 1999, includes merger, repositioning and other charges and gains on the sales of our Laminate Systems business and our investment in AMP Incorporated common stock resulting in a net after-tax charge of $624 million, or $0.78 per share.

Item 7.    Management's Discussion and Analysis of Financial Condition and
                 Results of Operations

BUSINESS OVERVIEW

      This Business Overview provides a summary of Honeywell's four reportable operating segments (Aerospace, Automation and Control Solutions, Specialty Materials and Transportation Systems), including how they generate income, the relevant economic and other factors impacting their results, and business challenges and areas of focus in both the short- and long-term. Each of these segments is comprised of various business units and product classes that serve multiple end markets. See Note 23 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data” for further information on our reportable segments and our definition of segment profit.

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Aerospace

      2004

  2003

  2002

      (Dollars in millions)
      

Net sales

     $ 9,748          $ 8,813          $ 8,855  
      

Segment profit

     $ 1,479          $ 1,221          $ 1,308  
      

Segment profit %

       15.2 %          13.9 %          14.8 %
      

                       

      Aerospace is a leading global supplier of aircraft engines, avionics, and related products and services for commercial airlines, business and regional aircraft, manned and unmanned military aircraft, and spacecraft. Our Aerospace portfolio includes Engines, Systems and Services (auxiliary power units; propulsion engines; environmental control systems; engine controls; repair and overhaul services; hardware; logistics; and electric power systems); Aerospace Electronic Systems (flight safety, communications, navigation, radar and surveillance systems; aircraft and airport lighting; management and technical services and advanced systems and instruments); and Aircraft Landing Systems (aircraft wheels and brakes). Aerospace sells its products to original equipment (OE) manufacturers in the commercial air transport and business and regional aircraft segments, as well as spare parts into the aftermarket (principally to aircraft operators). The United States Government is also a major customer for our defense and space products.

      Economic and Other Factors—Aerospace's operating results are principally driven by the global demand for air travel as reflected in new aircraft production, as well as spare parts and maintenance and repair services for aircraft currently in use. Aircraft production by commercial air transport OE manufacturers, business and regional jet deliveries, as well as global flying hours and airline profitability, are the principal factors that drive our commercial aerospace operating results. U.S. Government appropriations for defense and space programs and military activity are critical factors impacting our defense and space operating results.

      Business Challenges/Areas of Focus—Aerospace's primary business challenges and areas of focus include:

Continuing to grow the sales and profitability of the commercial aerospace aftermarket as the worldwide airline industry struggles to regain and maintain profitable operations.
 
Securing Honeywell product content on new aircraft platforms.
 
Making our product development process faster and less costly to meet increasing customer requirements while continuing to reduce recurring manufacturing costs.
 
Continuing to design equipment that enhances the safety, performance and durability of aircraft, while reducing weight and operating costs.
 
Utilizing our systems engineering expertise for continued growth in Network Centric Warfare initiatives with the U.S. Government.

Automation and Control Solutions (ACS)

      2004

  2003

  2002

      (Dollars in millions)
      

Net sales

     $ 8,031          $ 7,464          $ 6,978  
      

Segment profit

     $ 894          $ 843          $ 860  
      

Segment profit %

       11.1 %          11.3 %          12.3 %
      

                       

      ACS provides innovative solutions that make homes, buildings, industrial sites and airport facilities more efficient, safe and comfortable. Our ACS portfolio includes Automation and Control Products (controls for heating, cooling, indoor air quality, ventilation, humidification and home automation; advanced software applications for home/building control and optimization; sensors, switches, control systems and instruments for measuring pressure, air flow, temperature, electrical current; and security and fire detection, access control, video surveillance and remote patient monitoring systems); Building Solutions (installs, maintains and upgrades systems that keep buildings safe, comfortable and productive); and Process Solutions (provides a full range of automation and control solutions for

16


industrial plants, offering advanced software and automation systems that integrate, control and monitor complex processes in many types of industrial settings).

      Economic and Other Factors—ACS' operating results are principally driven by global residential and nonresidential construction, industrial production, capital spending on process and building automation, and fire and security concerns and regulations.

      Business Challenges/Areas of Focus—ACS' primary business challenges and areas of focus include:

Extending technology leadership: lowest total installed cost, integrated solutions within our security, fire and sensors product portfolios.
 
Defending and extending our installed base through customer productivity and globalization.
 
Sustaining strong brand recognition.
 
Continuing to invest in sales and marketing resources and new product development capabilities to drive profitable growth.
 
Integrating Novar plc's Intelligent Building Systems division into our life safety, building controls, security and related service businesses (acquisition of Novar plc expected to be completed in the first quarter of 2005).

Specialty Materials

      2004

  2003

  2002

      (Dollars in millions)
      

Net sales

       $ 3,497          $ 3,169          $ 3,205  
      

Segment profit

       $ 184          $ 136          $ 90  
      

Segment profit %

         5.3 %          4.3 %          2.8 %
      

                       

      Specialty Materials develops and manufactures high-purity, high-quality and high-performance chemicals and materials for applications in the automotive, healthcare, agricultural, packaging, fibers, refrigeration, semiconductor, wax and adhesives markets. Specialty Materials' product portfolio includes fluorocarbons, specialty films, advanced fibers, customized research chemicals and intermediates and electronic materials and chemicals. Specialty Materials' core growth businesses are Chemicals, Electronic Materials and Performance Products.

      Economic and Other Factors—Specialty Materials' operating results are principally driven by global gross domestic product, plant capacity utilization and the costs of raw materials including natural gas and benzene. We expect raw material costs to remain at historically high levels in 2005 and will continue to attempt to offset raw material cost increases with price increases where feasible.

      Business Challenges/Areas of Focus—Specialty Materials' primary business challenges and areas of focus include:

Sharpening the focus on core growth platforms to drive improved profitability through new product applications and introductions.
 
Continuing to restructure and exit non-core commodity lines of business with minimal or no differentiating technology and/or exposure to raw material cost volatility.
 
Continuing to improve manufacturing productivity.

Transportation Systems

      2004

  2003

  2002

      (Dollars in millions)
      

Net sales

       $ 4,323          $ 3,650          $ 3,184  
      

Segment profit

       $ 575          $ 461          $ 393  
      

Segment profit %

         13.3 %          12.6 %          12.3 %

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      Transportation Systems provides automotive products that improve the performance, efficiency, and appearance of cars, trucks, and other vehicles through state-of-the-art technologies, world class brands and global solutions to our customers needs. Our Transportation Systems' portfolio includes Honeywell Turbo Technologies (Garrett® turbochargers and charge-air and thermal systems); the Consumer Products Group (car care products including anti-freeze (Prestone®), filters (Fram®), spark plugs (Autolite®), and cleaners, waxes and additives (Holts®)); and Friction Materials (friction materials and related brake system components (Bendix® and Jurid®)). Transportation Systems sells its products to OE automotive and truck manufacturers (e.g., BMW, Caterpillar, Daimler-Chrysler, Ford, Volkswagen), wholesalers and distributors and through the retail aftermarket.

      Economic and Other Factors—Transportation Systems' operating results are principally driven by worldwide automobile and truck production and the global demand for automobiles and trucks equipped with turbochargers to enhance power, increase engine efficiency and lower emissions.

      Business Challenges/Areas of Focus—Transportation Systems' primary business challenges and areas of focus include:

Sustaining superior turbocharger technology.
 
Increasing market penetration and share of diesel and gasoline turbocharger OEM demand.
 
Expanding and strengthening established strong product brands in the Consumer Products Group business.
 
Revitalizing our Friction Materials business.

CRITICAL ACCOUNTING POLICIES

      The preparation of our consolidated financial statements in accordance with generally accepted accounting principles is based on the selection and application of accounting policies that require us to make significant estimates and assumptions about the effects of matters that are inherently uncertain. We consider the accounting policies discussed below to be critical to the understanding of our financial statements. Actual results could differ from our estimates and assumptions, and any such differences could be material to our consolidated financial statements.

      We have discussed the selection, application and disclosure of these critical accounting policies with the Audit Committee of our Board of Directors and our Independent Registered Public Accountants. There were no new accounting standards effective in 2004 which had a material impact on our consolidated financial statements.

      Contingent Liabilities—We are subject to a number of lawsuits, investigations and claims (some of which involve substantial dollar amounts) that arise out of the conduct of our global business operations or those of previously owned entities. These contingencies relate to product liabilities, including asbestos, commercial transactions, government contracts and environmental health and safety matters. We recognize a liability for any contingency that is probable of occurrence and reasonably estimable. We continually assess the likelihood of any adverse judgments or outcomes to our contingencies, as well as potential amounts or ranges of probable losses, and recognize a liability, if any, for these contingencies based on a careful analysis of each matter with the assistance of outside legal counsel and, if applicable, other experts. Such analysis includes making judgments concerning matters such as the costs associated with environmental matters, the outcome of negotiations, the number and cost of pending and future (where estimable) asbestos claims, and the impact of evidentiary requirements. Because most contingencies are resolved over long periods of time, liabilities may change in the future due to new developments or changes in our settlement strategy. For a discussion of our contingencies related to shareowners litigation, environmental and asbestos matters, including management's judgment applied in the recognition and measurement of specific liabilities, see Notes 1 and 21 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data”.

      Insurance for Asbestos Related Liabilities—In connection with recognition of liabilities for asbestos related matters, we record asbestos related insurance recoveries that are deemed probable. In assessing the probability of insurance recovery, we make judgments concerning insurance coverage

18


that we believe are reasonable and consistent with our historical dealings with our insurers, our knowledge of any pertinent solvency issues surrounding insurers and various judicial determinations relevant to our insurance programs. We have approximately $1.3 billion in insurance coverage remaining that can be specifically allocated to North American Refractories Company (NARCO) related asbestos liabilities. We also have $1.9 billion in coverage remaining for Bendix related asbestos liabilities although there are gaps in our coverage due to insurance company insolvencies, a comprehensive policy buy-back settlement with Equitas and certain uninsured periods, resulting in approximately 50 percent of these claims being reimbursable by insurance. Our insurance is with both the domestic insurance market and the London excess market. While the substantial majority of our insurance carriers are solvent, some of our individual carriers are insolvent, which has been considered in our analysis of probable recoveries. Projecting future events is subject to various uncertainties that could cause the insurance recovery on asbestos related liabilities to be higher or lower than that projected and recorded. Given the inherent uncertainty in making future projections, we reevaluate our projections concerning our probable insurance recoveries in light of any changes to the projected liability, our recovery experience or other relevant factors that may impact future insurance recoveries. See Note 21 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data” for a discussion of management's judgments applied in the recognition and measurement of insurance recoveries for asbestos related liabilities.

      Defined Benefit Pension Plans—We maintain defined benefit pension plans covering a majority of our employees and retirees. For financial reporting purposes, net periodic pension expense (income) is calculated based upon a number of actuarial assumptions including a discount rate for plan obligations and an expected rate of return on plan assets. We consider current market conditions, including changes in investment returns and interest rates, in making these assumptions. We determine the expected long-term rate of return on plan assets utilizing historic plan asset returns over varying long-term periods combined with current market conditions and broad asset mix considerations (see Note 22 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data” for actual and targeted asset allocation percentages for our pension plans). The expected rate of return on plan assets is a long-term assumption and generally does not change annually. The discount rate reflects the market rate for high-quality fixed-income investments on our annual measurement date (December 31) and is subject to change each year. The expected rate of return on pension assets and discount rate were determined in accordance with consistent methodologies as described in Note 22 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data”.

      The key assumptions used in developing our 2004, 2003 and 2002 net periodic pension expense (income) for our U.S. plans included the following:

      2004

  2003

  2002

      

Discount rate

       6.00 %        6.75 %        7.25 %
      

Assets:

                       
      

Expected rate of return

       9 %        9 %        10 %
      

Actual rate of return

       13 %        23 %        (8 )%
      

Actual 10 year average annual compounded rate of return

       11 %        10 %        9 %
      

                       

      The reduction in the discount rate in both 2004 and 2003 reflects the lower market interest rate environment for high-quality fixed income debt instruments. The discount rate is also volatile because it is determined based upon the prevailing rate as of the measurement date. Due to continuing declines in interest rates, we will use a 5.875 percent discount rate in 2005. The expected rate of return on plan assets was reduced from 10 to 9 percent for 2003 to reflect the impact of the poor performance of the equity markets during the three year period ended December 31, 2002. As equity markets have stabilized in 2003 and 2004, we plan to continue to use an expected rate of return of 9 percent for 2005. The unrecognized net losses for our U.S. pension plans were $2.6 billion at December 31, 2004, down from $3.2 billion at December 31, 2003. These unrecognized losses mainly result from actual plan asset returns below expected rates of return during 2002, 2001 and 2000 and from lower discount rates and are being systematically recognized in future net periodic pension expense in accordance with Statement of Financial Accounting Standards No. 87, “Employers Accounting for Pensions” (SFAS

19


No. 87). Under SFAS No. 87, we use the market-related value of plan assets reflecting changes in the fair value of plan assets over a three-year period. Further, unrecognized losses in excess of 10 percent of the greater of the market-related value of plan assets or the plans projected benefit obligation are recognized over a six-year period. Net periodic pension expense for our U.S. pension plans is expected to be $320 million in 2005, a $56 million decrease from 2004 due principally to a decrease in the amortization of unrecognized losses. The decline in the amortization of unrecognized losses results principally from actual plan asset returns higher than the expected rate of return in 2003 and 2004.

      We made voluntary contributions of $40, $670 and $830 million to our U.S. pension plans in 2004, 2003 and 2002, respectively. The 2003 and 2002 voluntary contributions were made to improve the funded status of the plans which had been impacted by the poor performance of the equity markets during the three-year period ended December 31, 2002, as well as the declining interest rate environment. Future plan contributions are dependent upon actual plan asset returns and interest rates. Assuming that actual plan returns are consistent with our expected plan return of 9 percent in 2005 and beyond, and that interest rates remain constant, we would not be required to make any contributions to our U.S. pension plans for the foreseeable future.

      Changes in net periodic pension expense may occur in the future due to changes in our expected rate of return on plan assets and discount rate resulting from economic events. The following table highlights the sensitivity of our U.S. pension obligations and expense to changes in these assumptions, assuming all other assumptions remain constant:

Change in Assumption

     Impact on Annual
Pension Expense

     Impact on PBO

0.25 percentage point decrease in discount rate

     Increase $50 million      Increase $300 million

0.25 percentage point increase in discount rate

     Decrease $50 million      Decrease $300 million

0.25 percentage point decrease in expected rate of return on assets

     Increase $25 million     

0.25 percentage point increase in expected rate of return on assets

     Decrease $25 million     

       

      SFAS No. 87 requires recognition of an additional minimum pension liability if the fair value of plan assets is less than the accumulated benefit obligation at the end of the plan year. In 2004, we recorded a non-cash adjustment to equity through accumulated other nonowner changes of $15 million ($19 million on a pretax basis) which increased the additional minimum pension liability. In 2003, we recorded a non-cash adjustment to equity through accumulated other nonowner changes of $369 million ($604 million on a pretax basis) to reduce the additional minimum pension liability by $304 million and reinstate a portion of our pension assets ($300 million) written off as a result of the prior year's minimum pension liability adjustment. The 2003 adjustment resulted from an increase in our pension assets in 2003 due to the improvement in equity markets and our contribution of $670 million to our U.S. plans. In 2002, due to the poor performance of the equity markets which adversely affected our pension assets and a decline in the discount rate, we recorded a non-cash adjustment to equity through accumulated other nonowner changes of $606 million ($956 million on a pretax basis) which increased the additional minimum pension liability. Equity market returns and interest rates significantly impact the funded status of our pension plans. Based on future plan asset performance and interest rates, additional adjustments to equity may be required.

      Long-Lived Assets (including Tangible and Definite-Lived Intangible Assets)—To conduct our global business operations and execute our business strategy, we acquire tangible and intangible assets. We periodically evaluate the recoverability of the carrying amount of our long-lived assets (including property, plant and equipment and definite-lived intangible assets) whenever events or changes in circumstances indicate that the carrying amount of a long-lived asset group may not be fully recoverable. These events or changes in circumstances include business plans and forecasts, economic or competitive positions within an industry, as well as current operating performance and anticipated future performance based on a business' competitive position. An impairment is assessed when the undiscounted expected future cash flows derived from an asset are less than its carrying amount. Impairment losses are measured as the amount by which the carrying value of a long-lived asset exceeds its fair value and are recognized in earnings. We continually apply our best judgment

20


when applying the impairment rules to determine the timing of the impairment test, the undiscounted cash flows used to assess impairment, and the fair value of an impaired long-lived asset group. The dynamic economic environment in which each of our businesses operate and the resulting assumptions used to estimate future cash flows, such as economic growth rates, industry growth rates, product life cycles, selling price changes and cost inflation can significantly influence and impact the outcome of all impairment tests. For a discussion of the result of management's judgment applied in the recognition and measurement of impairment charges see the repositioning and other charges section of this MD&A.

      Income Taxes—The future tax benefit arising from net deductible temporary differences and tax carryforwards was $1.7 and $1.8 billion at December 31, 2004 and 2003, respectively. We believe that our earnings during the periods when the temporary differences become deductible will be sufficient to realize the related future income tax benefits. For those jurisdictions where the expiration date of tax carryforwards or the projected operating results indicate that realization is not likely, a valuation allowance is provided.

      In assessing the need for a valuation allowance, we consider all available positive and negative evidence, including past operating results, estimates of future taxable income and the feasibility of ongoing tax planning strategies. Significant management judgment is required in determining the provision for income taxes and, in particular, any valuation allowance recorded against our deferred tax assets. Additionally, valuation allowances related to deferred tax assets can be impacted by changes to tax laws and future taxable income levels. In the event we determine that we will not be able to realize our deferred tax assets in the future, we will reduce such amounts through a charge to income in the period that such determination is made. Conversely, if we determine that we will be able to realize deferred tax assets in excess of the carrying amounts, we will decrease the recorded valuation allowance through a credit to income in the period that such determination is made.

      Sales Recognition on Long-Term Contracts—In 2004, we recognized approximately 8 percent of our total net sales using the percentage-of-completion method for long-term contracts in our Automation and Control Solutions and Aerospace reportable segments. The percentage-of-completion method requires us to make judgments in estimating contract revenues, contract costs and progress toward completion. These judgments form the basis for our determinations regarding overall contract value, contract profitability and timing of revenue recognition based on measured progress toward contract completion. Revenue and cost estimates are monitored on an ongoing basis and revised based on changes in circumstances. Anticipated losses on long-term contracts are recognized when such losses become evident. We maintain financial controls over the customer qualification, contract pricing and cost estimation processes to reduce the risk of contract losses.

      Aerospace Customer Incentives—Consistent with other suppliers to commercial aircraft manufacturers and airlines, we provide sales incentives to commercial aircraft manufacturers and airlines in connection with their selection of our aircraft wheel and braking system hardware and auxiliary power units for installation on commercial aircraft. These incentives consist of free or deeply discounted products, product credits and upfront cash payments. The cost of these incentives are capitalized at the time we deliver the products to our customers or, in the case of product credits, at the time the credit is issued, or in the case of upfront cash payments, at the time the payment is made. In the case of free or deeply discounted product, the cost to manufacture less any amount recovered from the airframe manufacturer or airline is capitalized. Product credits and upfront cash payments are capitalized at exchanged value. Research, design, development and qualification costs related to these products are expensed as incurred, unless contractually guaranteed of reimbursement. The cost of the sales incentives described above is capitalized because the selection of our aircraft wheel and braking system hardware and auxiliary power units for installation on commercial aircraft results in the creation of future revenues and cash flows through aftermarket sales to fulfill long-term product maintenance requirements mandated by the Federal Aviation Administration (FAA) and other similar international organizations over the useful life of the aircraft. Once our products are certified and selected on an aircraft, the recovery of our investment is virtually guaranteed over the useful life of the aircraft. The likelihood of displacement by an alternative supplier is remote due to contractual sole-sourcing, the high cost to alternative suppliers and aircraft operators of product retrofits, and/or rigorous regulatory

21


specifications, qualification and testing requirements. Amounts capitalized at December 31, 2004, 2003 and 2002 were $776, $719 and $662 million, respectively, and are being amortized over their useful lives on a straight-line basis, up to 25 years, representing the estimated minimum service life of the aircraft. This useful life is the period over which we are virtually assured to earn revenues from the aftermarket sales of certified products necessary to fulfill the maintenance required by the FAA and other similar international organizations. We classify the amortization expense associated with free and discounted products as cost of goods sold and the amortization expense associated with product credits and upfront cash payments as a reduction of sales. We regularly evaluate the recoverablitity of capitalized amounts whenever events or changes in circumstances indicate that the carrying amount of the incentives may not be fully recoverable. There were no impairment charges related to these capitalized incentives recognized during 2004, 2003 and 2002. For additional information see Note 13 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data.”

RESULTS OF OPERATIONS

Net Sales

      2004

  2003

  2002

      (Dollars in millions)
      

Net sales

     $ 25,601          $ 23,103          $ 22,274  
      

% change compared with prior year

       11 %          4 %          (6 )%
      

                       

      The change in net sales in 2004 and 2003 is attributable to the following:

      2004
Versus
2003

  2003
Versus
2002

      

Acquisitions

       1 %        3 %
      

Divestitures

       (1 )        (2 )
      

Price

                 
      

Volume

       8           
      

Foreign Exchange

       3          3  
          
        
 
      

       11 %        4 %
          
        
 
      

               

      A discussion of net sales by reportable segment can be found in the Review of Business Segments section of this MD&A.

Cost of Products and Services Sold

      2004

  2003

  2002

      (Dollars in millions)
      

Cost of products and services sold

     $ 20,585          $ 18,235          $ 17,615  
      

Gross Margin %

       19.6 %          21.1 %          20.9 %
      

                       

      Gross margin decreased in 2004 by 1.5 percentage points compared with 2003. The decrease resulted primarily from an increase in net repositioning and other charges of $349 million, higher pension and other postretirement benefits expense of $249 million and an increase in research and development expense of $166 million, partially offset by an increase in sales of higher-margin products and services, mainly in our Aerospace reportable segment. Gross margin increased in 2003 by 0.2 percentage points compared with 2002. The increase resulted primarily from a decrease in net repositioning and other charges of $289 million partially offset by higher pension expense and a decrease in sales of higher-margin products and services, mainly in our Aerospace and Automation and Control Solutions reportable segments.

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Selling, General and Administrative Expenses

      2004

  2003

  2002

      (Dollars in millions)
      

Selling, general and administrative expenses

     $ 3,316          $ 2,950          $ 2,757  
      

Percent of sales

       13.0 %          12.8 %          12.4 %
      

                       

      Selling, general and administrative expenses increased by $366 million, or 12 percent in 2004 compared with 2003 due to an increase in general and administrative expenses of $155 million due in part to higher spending for information technology systems, an increase in selling expenses of $136 million from higher sales and an increase in pension and other postretirement benefits expense of $54 million. Selling, general and administrative expenses increased by $193 million, or 7 percent in 2003 compared with 2002 due primarily to an increase in general and administrative expenses of $120 million due in part to an increase in other employee benefit expenses, and higher pension and other postretirement benefits expense of $56 million.

      2004

  2003

  2002

      (Dollars in millions)
      

Pension and other postretirement benefits expense (income) included in cost of goods sold and selling, general and administrative expenses

     $ 628        $ 325        $ (11 )
      

Increase compared with prior year

     $ 303        $ 336        $ 154  
      

                       

      Pension expense increased by $276 and $290 million in 2004 and 2003, respectively, mainly due to the following:

A decrease in the market-related value of our pension plan assets during the period 2000 to 2002 due to the poor performance of the equity markets which adversely affected our pension fund assets during this period.
 
A systematic recognition of higher losses resulting mainly from actual plan asset returns below the expected rate of return during the period 2000 to 2002.
 
A reduction in 2003 in the expected rate of return on plan assets from 10 to 9 percent in response to the continued deterioration in financial market returns in 2002.
 
A decrease in the discount rate for each of the years 2001 (7.75 percent), 2002 (7.25 percent), 2003 (6.75 percent) and 2004 (6.00 percent).

      Using an expected long-term rate of return of 9 percent and a discount rate of 5.875 percent, pension expense for our U.S. plans is expected to be $320 million in 2005, a decrease of $56 million compared with 2004.

(Gain) Loss on Sale of Non-Strategic Businesses

      2004

  2003

  2002

      (Dollars in millions)
      

(Gain) loss on sale of non-strategic businesses

     $ (255 )      $ (38 )      $ 124  
      

                       

      Gain on sale of non-strategic businesses of $255 million in 2004 represents the pretax gains on the sales of our Security Monitoring and VCSEL Optical Products businesses in our Automation and Control Solutions reportable segment of $215 and $36 million, respectively. The gain also includes adjustments of $19 million related to businesses sold in prior periods and the pretax loss of $15 million on the sale of our Performance Fibers business in our Specialty Materials reportable segment. The dispositions of these businesses did not materially impact net sales and segment profit in 2004 compared with 2003. Gain on sale of non-strategic businesses of $38 million in 2003 represents the net pretax gain on the dispositions of certain Specialty Materials (Engineering Plastics, Rudolstadt and Metglas) and Aerospace (Honeywell Aerospace Defense Services) businesses. The dispositions of these businesses did not materially impact net sales and segment profit in 2003 compared with 2002.

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Asbestos Related Litigation Charges, Net of Insurance

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Asbestos related litigation charges, net of insurance

     $ 76        $        $ 1,548  
      

                       

      In 2004, we recognized charges totaling $76 million primarily for Bendix related asbestos claims filed and defense costs incurred during 2004, net of insurance recoveries. The charges include an update of expected resolution values for pending Bendix claims and are net of an additional $47 million of NARCO insurance deemed probable of recovery. In 2002, asbestos related litigation charges, net of insurance related to costs associated with asbestos claims related to NARCO. See Asbestos Matters in Note 21 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data” for further discussion.

Business Impairment Charges

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Business impairment charges

     $ 42        $        $ 877  
      

                       

      Business impairment charges in 2004 relates principally to the write-down of property, plant and equipment of our Performance Fibers business in our Specialty Materials reportable segment. The Performance Fibers business was sold in the fourth quarter of 2004. Business impairment charges in 2002 related to the write-down of property, plant and equipment of businesses in our Specialty Materials and Automation and Control Solutions reportable segments and of our Friction Materials business. See the repositioning and other charges section of this MD&A for further details.

Equity in (Income) Loss of Affiliated Companies

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Equity in (income) loss of affiliated companies

     $ (82 )      $ (38 )      $ (42 )
      

                       

      Equity income increased by $44 million in 2004 compared with 2003 due primarily to an improvement in earnings from our UOP process technology joint venture (UOP). Equity income decreased by $4 million in 2003 compared with 2002 due to a charge of $2 million in 2003 related to the sale of a Specialty Materials' equity investee's investment. Also, 2002 included income of $15 million resulting from exiting joint ventures in our Aerospace and Transportation Systems reportable segments partially offset by a charge of $13 million for severance actions by UOP.

Other (Income) Expense

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Other (income) expense

     $ (92 )      $ 19        $ (4 )
      

                       

      Other income increased by $111 million in 2004 compared with 2003 due principally to a decrease in foreign exchange losses of $93 million in the current year due to a reduction in foreign exchange exposures resulting in losses in 2003 due to a weak U.S. dollar, a gain of $27 million related to the settlement of a patent infringement lawsuit and an increase in interest income of $13 million from higher cash balances, partially offset by the inclusion of a gain of $20 million in the prior year related to the settlement of a patent infringement lawsuit. Other expense increased by $23 million in 2003 compared with 2002 due principally to an increase of $65 million in foreign exchange losses resulting from weakness in the U.S. dollar mainly against the EURO partially offset by a gain of $20 million related to a settlement of a patent infringement lawsuit and an increase of $19 million in interest income from higher cash balances.

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Interest and Other Financial Charges

      2004

  2003

  2002

      (Dollars in millions)
      

Interest and other financial charges

     $ 331          $ 335          $ 344  
      

% change compared with prior year

       (1 )%          (3 )%          (15 )%
      

                       

      Interest and other financial charges decreased by 1 percent in 2004 compared with 2003 due principally to lower average short-term debt outstanding in the current year. Interest and other financial charges decreased by 3 percent in 2003 compared with 2002 due principally to lower average interest rates.

Tax Expense (Benefit)

      2004

  2003

  2002

      (Dollars in millions)
      

Tax expense (benefit)

     $ 399          $ 296          $ (725 )
      

Effective tax (benefit) rate

       23.8 %          18.0 %          (76.7 )%
      

                       

      The effective tax (benefit) rate in 2004, 2003 and 2002 was different than the statutory rate of 35 percent due in part to tax benefits from export sales, favorable tax audit settlements and foreign tax planning strategies. The effective tax rate in 2003 also includes tax benefits expected to be realized as a result of the redesignation of our Friction Materials business from held for sale to held and used resulting from the termination of discussions with Federal-Mogul Corp. The effective (benefit) rate in 2002 included the tax benefit resulting from a higher deductible tax basis than book basis related to sales of our Advanced Circuits, PFC and Consumer Products businesses. The impact of tax benefits from export sales, U.S. tax credits and favorable audit settlements had a more favorable impact on our effective (benefit) rate in 2002 principally due to the relative amount of these benefits in comparison to the amount of our pretax loss in 2002. See Note 7 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data” for further information on taxes including a detailed effective tax rate reconciliation.

      The American Jobs Creation Act of 2004, signed into law in October 2004, provides for a variety of changes in the tax law including incentives to repatriate undistributed earnings of foreign subsidiaries, a phased elimination of the extra-territorial income exclusion, and a domestic manufacturing benefit. More specifically, the Act creates a temporary incentive for U.S. corporations to repatriate accumulated income earned outside the U.S. by providing an 85 percent dividends received deduction for certain dividends from controlled foreign corporations. The deduction is subject to a number of limitations and currently, uncertainty remains as to how to interpret numerous provisions in the Act. As such, we are not in a position to determine whether, and to what extent, we might repatriate foreign earnings. Based on our analysis to date, however, it is reasonably possible that we may repatriate some amount up to approximately $2.6 billion. We estimate the income tax effects of repatriating $2.6 billion to be approximately $150 to $350 million. Honeywell has not provided for U.S. federal income and foreign withholding taxes on $3.9 billion of undistributed earnings from non-U.S. operations as of December 31, 2004. Until our analysis of the Act is completed, we will continue to permanently reinvest those earnings. We expect to finalize our assessment later in 2005.

      The extra-territorial income exclusion (ETI) for foreign sales will be phased-out over two years beginning in 2005. The deduction for income from qualified domestic production activities will be phased-in from 2005 through 2010. Similar to the ETI benefit, the domestic manufacturing benefit has no effect on deferred tax assets and liabilities existing at the enactment date. Rather, the impact of this deduction will be reported in the period in which the deduction is claimed on our federal income tax return. We are currently assessing the details of the Act and the net effect of the phase-out of the ETI and the phase-in of this new deduction. We expect to complete our analysis later in 2005. Until such time, it is not possible to determine what impact this legislation will have on our consolidated tax accruals or effective tax rate.

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Net Income (Loss)

      2004

  2003

  2002

      (Dollars in millions,
except per share amounts)
      

Net income (loss)

     $ 1,281        $ 1,324        $ (220 )
      

Earnings (loss) per share of common stock—assuming dilution

     $ 1.49        $ 1.54        $ (0.27 )
      

                       

      The decrease of $0.05 per share in 2004 compared with 2003 relates primarily to increased charges for environmental matters primarily attributable to the denial of our appeal in the matter entitled Interfaith Community Organization et. al. v. Honeywell International Inc. et. al. (See Note 21 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data”) and higher pension and other postretirement benefits expense, partially offset by an increase in segment profit across all reportable segments. The increase of $1.81 per share in 2003 compared with 2002 mainly relates to a decrease in repositioning and other charges partially offset by the impact of higher pension expense and lower sales of higher-margin products and services, principally in our Aerospace and Automation and Control Solutions reportable segments.

Review of Business Segments

      2004

  2003

  2002

      (Dollars in millions)
      

Net Sales

                       
      

Aerospace

     $ 9,748        $ 8,813        $ 8,855  
      

Automation and Control Solutions

       8,031          7,464          6,978  
      

Specialty Materials

       3,497          3,169          3,205  
      

Transportation Systems

       4,323          3,650          3,184  
      

Corporate

       2          7          52  
          
        
        
 
      

     $ 25,601        $ 23,103        $ 22,274  
          
        
        
 
      

Segment Profit

                       
      

Aerospace

     $ 1,479        $ 1,221        $ 1,308  
      

Automation and Control Solutions

       894          843          860  
      

Specialty Materials

       184          136          90  
      

Transportation Systems

       575          461          393  
      

Corporate

       (158 )        (142 )        (154 )
          
        
        
 
      

     $ 2,974        $ 2,519        $ 2,497  
          
        
        
 
      

                       

      A reconciliation of segment profit to income (loss) before taxes and cumulative effect of accounting change follows:

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Segment profit

     $ 2,974        $ 2,519        $ 2,497  
      

Gain (loss) on sale of non-strategic businesses

       255          38          (124 )
      

Asbestos related litigation charges, net of insurance

       (76 )                 (1,548 )
      

Business impairment charges

       (42 )                 (877 )
      

Repositioning and other charges(1)

       (646 )        (276 )        (606 )
      

Pension and other postretirement benefits (expense) income(1)

       (628 )        (325 )        11  
      

Equity in income (loss) of affiliated companies

       82          38          42  
      

Other income (expense)

       92          (19 )        4  
      

Interest and other financial charges

       (331 )        (335 )        (344 )
          
        
        
 
      

Income (loss) before taxes and cumulative effect of accounting change

     $ 1,680        $ 1,640        $ (945 )
          
        
        
 

26


      

                       


     
(1)     Amounts included in cost of products and services sold and selling, general and administrative expenses.

Aerospace

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Net sales

     $ 9,748          $ 8,813          $ 8,855  
      

% change compared with prior year

       11 %          %          (8 )%
      

Segment profit

     $ 1,479          $ 1,221          $ 1,308  
      

% change compared with prior year

       21 %          (7 )%          (18 )%
      

                       

      Aerospace sales by major customer end-markets were as follows:

    % of Aerospace
Sales

  % Change in
Sales

Market Segment

  2004

  2003

  2002

  2004
Versus
2003

  2003
Versus
2002

                                       

Commercial:

                                       

Air transport aftermarket

       22 %        21 %        20 %        19 %        (1 )%

Air transport original equipment

       9          9          11          5          (16 )

Regional transport aftermarket

       8          9          9          11          (8 )

Regional transport original equipment

       3          2          2          48          (15 )

Business and general aviation aftermarket

       8          8          8          13          6  

Business and general aviation original equipment

       7          6          8          27          (21 )

Defense and Space:

                                       

Defense and space aftermarket

       13          13          11          7          16  

Defense and space original equipment

       30          32          31          6          4  
        
        
        
        
        
 

Total

       100 %        100 %        100 %        11 %        %
        
        
        
        
        
 

                                       

      Details of the changes in sales for both 2004 and 2003 by customer end-markets were as follows:

Despite the continuing financial problems being experienced by many of the commercial airlines, air transport aftermarket sales improved substantially in 2004 primarily related to a 10 percent increase in global flying hours, the reintroduction of aircraft into service which were previously parked in the desert, a replenishment of spare parts inventories by the airlines and growth in low cost carriers. Additionally, global flying hours in 2003 were adversely impacted as a result of the SARS epidemic. Sales also improved due to an increase in upgrades and retrofits of avionics equipment (ground proximity warning systems) to meet new regulatory standards. Air transport aftermarket sales were adversely impacted in 2003 by a decrease in global flying hours of 1 percent and the financial problems being experienced by many of the commercial airlines. The global flying hours and sales decline trends began in 2001 and was exacerbated by the abrupt downturn in the aviation industry following the terrorists attacks on September 11, 2001 and the SARS epidemic in 2003. While sales of repair and overhaul services started to improve in 2003 signaling increased maintenance and out-sourcing activity by the major airlines, discretionary spending by airlines for purchases of spare parts for replacements and upgrades continued to be weak.
 
Air transport original equipment (OE) sales increased in 2004 primarily reflecting higher aircraft deliveries by our OE customers (primarily Airbus and Boeing) as aircraft orders by the commercial airlines began to improve. Air transport OE sales decreased significantly in 2003 reflecting dramatically lower deliveries by our OE customers due to reduced aircraft orders by commercial airlines.
 
Regional transport aftermarket sales increased in 2004 due primarily to an increase in fleet sizes and routes of regional carriers and the introduction of the Primus Epic integrated avionics

27


  system. Regional aftermarket sales decreased in 2003 due mainly to lower sales of spare parts to regional airline operators.
   
Business and general aviation aftermarket sales were higher in 2004 as an improving economy drove increased utilization of corporate aircraft. Also, there was an increase in upgrade activity in avionics equipment (RVSM) to meet new regulatory standards. Business and general aviation aftermarket sales also increased in 2003 largely due to higher repair and overhaul activity in the fractional jet market.
 
Business and general aviation OE sales improved in 2004 due primarily to deliveries of the Primus Epic integrated avionics system and HTF7000 engine to business jet OE manufacturers. Business and general aviation OE sales were lower in 2003 reflecting a decline in projected deliveries of business jet airplanes due to weakness in the demand for fractional interests in aircraft and corporate profitability.
 
Defense and space OE sales increased in both 2004 and 2003 due principally to war-related activities, continued growth in precision munitions and increases in restricted space programs.
 
Defense and space aftermarket sales were strong in both 2004 and 2003 driven by war-related activities resulting in increases in repairs, platform upgrades and modifications for fixed, rotary wing and ground vehicles.

      Aerospace segment profit in 2004 increased by 21 percent compared with 2003 due primarily to an increase in sales of higher margin commercial aftermarket products and services and volume growth. This increase was partially offset by higher development expense associated with new programs and an increase in spending for information technology systems. Aerospace segment profit in 2003 decreased by 7 percent compared with 2002 due mainly to lower sales of commercial original equipment and higher-margin commercial aftermarket spare parts.

      Trends which may impact Aerospace operating results in 2005 include:

Global flying hours improved by 10 percent in 2004 and are expected to increase again in 2005 (5 to 6 percent).
 
The financial condition of major commercial airlines continues to be a concern due mainly to high fuel costs and intense fare competition.
 
The extent to which increased military activity is offset by lower OE sales due to program completions and reductions.
 
The magnitude of an expected increase in aircraft orders and deliveries in the air transport, business and general aviation segments.

Automation and Control Solutions

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Net sales

     $ 8,031          $ 7,464          $ 6,978  
      

% change compared with prior year

       8 %          7 %          (3 )%
      

Segment profit

     $ 894          $ 843          $ 860  
      

% change compared with prior year

       6 %          (2 )%          11 %
      

                       

      Automation and Control Solutions sales in 2004 increased by 8 percent compared with 2003 due to higher volumes of 5 percent and the favorable effect of foreign exchange of 4 percent, partially offset by the impact of lower prices of 1 percent. Sales increased by 9 percent for our Automation and Control Products businesses due principally to strong sales of fire solutions, environmental controls and sensor products, and the favorable effects of foreign exchange and acquisitions. Sales for our Process Solutions business increased by 8 percent due primarily to the favorable effect of foreign exchange and improvement in industrial production and capital spending. Sales for our Building Solutions business increased by 5 percent due primarily to the favorable effect of foreign exchange and the impact of investments in sales and marketing initiatives, partially offset by the divestiture of our Security

28


Monitoring business. Automation and Control Solutions sales in 2003 increased by 7 percent compared with 2002 due to favorable effects of foreign exchange of 5 percent and acquisitions, net of the disposition of our Consumer Products business, of 4 percent, partially offset by the impact of lower prices and volumes of 1 percent each. Sales increased by 11 percent for our Automation and Control Products businesses as the favorable effects of foreign exchange and acquisitions, mainly Invensys Sensor Systems (Invensys), more than offset the impact of the disposition of our Consumer Products business and lower volumes. Sales for our Process Solutions business increased by 4 percent due to the favorable effect of foreign exchange partially offset by lower unit volumes. Sales for our Building Solutions business increased by 2 percent as the favorable effect of foreign exchange more than offset lower volumes due to continued softness in the non-residential construction market.

      Automation and Control Solutions segment profit in 2004 increased by 6 percent compared with 2003 due to the favorable effect of higher sales volumes partially offset by increased investments in sales and marketing initiatives and higher research and development costs to support new product introductions. Automation and Control Solutions segment profit in 2003 decreased by 2 percent compared with 2002 due mainly to the decline in higher-margin energy-retrofit and discretionary spot sales in our Building Solutions business, and increased research and development expense and investments in sales and marketing initiatives, mainly in our Automation and Control Products and Building Solutions businesses, respectively. Segment profit was also adversely impacted in 2003 by pricing pressures mainly in our Automation and Control Products and Process Solutions businesses.

      Trends which may impact Automation and Control Solutions operating results in 2005 include:

Extent, if any, of recovery in non-residential construction spending and capital spending on building and process automation.
 
Consolidation in the fire and security industry may result in increased competition.

Specialty Materials

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Net sales

     $ 3,497          $ 3,169          $ 3,205  
      

% change compared with prior year

       10 %          (1 )%          (3 )%
      

Segment profit

     $ 184          $ 136          $ 90  
      

% change compared with prior year

       35 %          51 %          61 %
      

                       

      Specialty Materials sales in 2004 increased by 10 percent compared with 2003 due to the impact of higher prices of 6 percent (mainly in our Nylon System business), higher volumes of 5 percent and the favorable effect of foreign exchange of 1 percent, partially offset by prior year divestitures, net of acquisitions, of 2 percent. Sales for our Chemicals business improved by 19 percent driven principally by continuing strong demand for our non-ozone depleting HFC products for refrigeration and air conditioning applications, as well as for blowing agents for insulation applications. Sales for our Electronic Materials business increased by 13 percent driven by improvement in the semiconductor industry. Sales for our Performance Products business were also higher by 13 percent due to strong demand for our Spectra fiber, principally from the U.S. military. Specialty Materials sales in 2003 decreased by 1 percent compared with 2002 due to the impact of the divestitures of our Advanced Circuits, PFC and Engineering Plastics businesses, net of the acquisition of BASF's nylon fiber business, of 6 percent partially offset by the favorable effects of foreign exchange of 3 percent and higher volumes of 2 percent. Higher volumes were principally driven by strong demand for Spectra fiber from the U.S. military, increasing demand for HFCs, a key component of many non-ozone depleting refrigerants and foam blowing agents and increased demand for electronic materials from the semiconductor industry. Volumes were adversely affected in 2003 by the temporary plant shutdowns in our Fluorocarbons and Nylon System businesses.

      Specialty Materials segment profit in 2004 increased by 35 percent compared with 2003 due principally to higher sales volumes and price increases, partially offset by higher raw material costs (principally phenol resulting from increases in benzene prices) mainly in our Nylon System business.

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Additionally segment profit in 2003 was adversely impacted by temporary plant shutdowns in our Fluorocarbons and Nylon System businesses. Specialty Materials segment profit in 2003 increased by 51 percent compared with 2002 due mainly to the impact of the prior year write-down of property, plant and equipment in several businesses, the benefits of cost actions including synergies from the nylon transaction, divestitures of non-strategic businesses and higher sales volumes. The increase was partially offset by higher raw material costs (mainly natural gas and phenol resulting from increases in benzene prices) and the impact of the temporary plant shutdowns in our Fluorocarbons and Nylon System businesses.

      Trends which may impact Specialty Materials operating results in 2005 include:

Continued excess global capacity in the production of nylon. The Nylon System business did not perform in accordance with our operating plan in 2004. We have taken certain repositioning actions in 2004 (see repositioning section of this MD&A) and are evaluating other alternatives. Additionally, we continue to evaluate strategic alternatives to maximize the value of this business.
 
Degree of volatility in significant raw material costs (natural gas and benzene).
 
Extent of change in order rates from global semiconductor customers.

Transportation Systems

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Net sales

     $ 4,323          $ 3,650          $ 3,184  
      

% change compared with prior year

       18 %          15 %          (8 )%
      

Segment profit

     $ 575          $ 461          $ 393  
      

% change compared with prior year

       25 %          17 %          28 %
      

                       

      Transportation Systems sales in 2004 increased by 18 percent compared with 2003 due primarily to a favorable sales mix and higher volumes of 12 percent and the favorable effect of foreign exchange of 6 percent. The increase in sales for the segment resulted principally from a 29 percent increase in sales in our Honeywell Turbo Technologies business due to a favorable sales mix and volume growth driven by increasing diesel penetration in Europe and strength in the North American truck segment, and the favorable effect of foreign exchange. Sales for our Consumer Products Group business increased by 7 percent driven by strong retail demand for our high-end products and recent introductions of new Autolite, FRAM and Prestone products and the favorable effect of foreign exchange and higher prices (offsetting incremental ethylene glycol raw material costs). Sales for our Friction Materials business increased by 7 percent largely due to the favorable effect of foreign exchange. Transportation Systems sales in 2003 increased by 15 percent compared with 2002 due mainly to the favorable effects of foreign exchange of 9 percent and a favorable sales mix and volume growth of 5 percent. The increase resulted mainly from a 27 percent increase in sales in our Honeywell Turbo Technologies business due to a favorable sales mix and volume growth of 15 percent as worldwide demand for our turbochargers continued to be strong and the favorable effect of foreign exchange of 12 percent.

      Transportation Systems segment profit in 2004 increased by 25 percent compared with 2003 due primarily to the effect of favorable sales mix and volume growth in our Honeywell Turbo Technologies business partially offset by higher raw material costs (mostly steel and other metals in each of the segment's businesses and ethylene glycol in our Consumer Products Group business). Transportation Systems segment profit in 2003 increased by 17 percent compared with 2002 as the effect of higher sales in our Honeywell Turbo Technologies business was partially offset by higher new product development and introduction and facility relocations expenses, and lower aftermarket sales at our Friction Materials business.

      Trends which may impact Transportation Systems operating results in 2005 include:

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Rate of increase in global diesel and gasoline turbocharger OEM demand arising from continued penetration of diesel passenger cars into the European market, and North America truck shipments.
 
The adoption of regulations aimed at reducing emissions.
 
Change in consumer spending for automotive aftermarket products.

Repositioning and Other Charges

      A summary of repositioning and other charges follows:

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Severance

     $ 85        $ 69        $ 270  
      

Asset impairments

       21          6          121  
      

Exit costs

       10          7          62  
      

Reserve adjustments

       (28 )        (69 )        (76 )
          
        
        
 
      

Total net repositioning charge

       88          13          377  
          
        
        
 
      

Asbestos related litigation charges, net of insurance

       76                   1,548  
      

Other probable and reasonably estimable legal and
environmental liabilities

       565          261          30  
      

Business impairment charges

       42                   877  
      

Customer claims and settlements of contract liabilities

       (10 )                 152  
      

Write-offs of receivables, inventories and other assets

       14          2          60  
      

Investment impairment charges

                2          15  
          
        
        
 
      

Total net repositioning and other charges

     $ 775        $ 278        $ 3,059  
          
        
        
 
      

                       

      The following table summarizes the pretax distribution of total net repositioning and other charges by income statement classification:

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Cost of products and services sold

     $ 621        $ 272        $ 561  
      

Selling, general and administrative expenses

       25          4          45  
      

Asbestos related litigation charges, net of insurance

       76                   1,548  
      

Business impairment charges

       42                   877  
      

Equity in (income) loss of affiliated companies

       6          2          13  
      

Other (income) expense

       5                   15  
          
        
        
 
      

     $ 775        $ 278        $ 3,059  
          
        
        
 
      

                       

      In 2004, we recognized repositioning charges totaling $116 million primarily for severance costs related to workforce reductions of 2,272 manufacturing and administrative positions across all of our reportable segments. Also, $28 million of previously established accruals, primarily for severance, were returned to income in 2004, due to fewer employee separations than originally planned associated with certain prior repositioning actions, resulting in reduced severance liabilities principally in our Automation and Control Solutions reportable segment.

      In 2003, we recognized repositioning charges totaling $82 million primarly for severance costs related to workforce reductions of 1,501 manufacturing and administrative positions across all of our reportable segments. Also, $69 million of previously established accruals, primarily for severance, were returned to income in 2003, due to fewer employee separations than originally planned associated with certain prior repositioning actions, resulting in reduced severance liabilities in our Automation and Control Solutions, Aerospace and Specialty Materials reportable segments.

31


      In 2002, we recognized repositioning charges totaling $453 million for workforce reductions across all of our reportable segments and our UOP process technology joint venture. The charge also related to costs for the planned shutdown and consolidation of manufacturing plants in our Specialty Materials and Automation and Control Solutions reportable segments. Severance costs related to announced workforce reductions of approximately 8,100 manufacturing and administrative positions. Asset impairments principally related to manufacturing plant and equipment held for sale and capable of being taken out of service and actively marketed in the period of impairment. Exit costs related principally to incremental costs to exit facilities, including lease termination losses negotiated or subject to reasonable estimation related mainly to closed facilities in our Automation and Control Solutions and Specialty Materials reportable segments. Also, $76 million of previously established severance accruals were returned to income in 2002, due to fewer employee separations than originally planned associated with certain prior repositioning actions and higher than expected voluntary employee attrition, resulting in reduced severance liabilities in our Aerospace, Automation and Control Solutions and Specialty Materials reportable segments.

      Our 2004 repositioning actions are expected to generate incremental pretax savings of approximately $75 million in 2005 compared with 2004 principally from planned workforce reductions. Cash expenditures for severance and other exit costs necessary to execute our repositioning actions were $164, $200 and $447 million in 2004, 2003 and 2002, respectively. Such expenditures for severance and other exit costs have been funded principally through operating cash flows. Cash expenditures for severance and other exit costs necessary to execute the remaining actions will approximate $100 million in 2005 and will be funded principally through operating cash flows.

      In 2004, we recognized a charge of $565 million for other probable and reasonably estimable legal and environmental liabilities. This includes $536 million for legacy environmental liabilities, primarily related to the denial of our appeal of the matter entitled Interfaith Community Organization, et. al. v. Honeywell International Inc., et al., and estimated liabilities for remediation of environmental conditions in and around Onondaga Lake in Syracuse, New York. Both of these environmental matters are discussed in further detail in Note 21 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data.” We recognized a charge of $29 million for various legal settlements including property damage claims in our Automation and Control Solutions reportable segment. We recognized a charge of $76 million primarily for Bendix related asbestos claims and defense costs incurred in 2004 including an update of expected resolution values with respect to pending claims. The charge was net of probable Bendix related insurance recoveries and an additional $47 million of NARCO insurance deemed probable of recovery. See Note 21 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data” for further discussion. We recognized an impairment charge of $42 million in the second quarter of 2004 related principally to the write-down of property, plant and equipment of our Performance Fibers business in our Specialty Materials reportable segment. This business was sold in December 2004. We recognized a charge of $14 million for the write-off of receivables, inventories and other assets. We also reversed a reserve of $10 million established in the prior year for a contract settlement.

      In 2003, we recognized a charge of $261 million for other probable and reasonably estimable legal and environmental liabilities. This included $235 million for environmental liabilities mainly related to the matter entitled Interfaith Community Organization, et al. v. Honeywell International Inc., et al. and for remediation of environmental conditions in and around Onondaga Lake in Syracuse, New York, both as discussed in Note 21 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data.” We also recognized a charge of $4 million in our Specialty Materials reportable segment including a loss on sale of an investment owned by an equity investee.

      In 2002, we recognized business impairment charges of $877 million related to businesses in our Specialty Materials and Automation and Control Solutions reportable segments, as well as our Friction Materials business. Based on current operating losses and deteriorating economic conditions in certain chemical and telecommunications end-markets, we performed impairment tests and recognized impairment charges of $785 million principally related to the write-down of property, plant and equipment held and used in our Nylon System, Performance Fibers and Metglas Specialty Materials businesses, as well as an Automation and Control Solutions communication business. We also

32


recognized impairment charges of $92 million related principally to the write-down of property, plant and equipment of our Friction Materials business, which was classified as assets held for disposal in Other Current Assets as of December 31, 2002. A plan of disposal of Friction Materials was adopted in 2001; in January 2003, we entered into a letter of intent to sell this business to Federal-Mogul Corp. The assets were reclassified from held for sale to held and used as of December 31, 2003 following the cessation of negotiations to sell our Friction Materials business to Federal-Mogul Corp. At that time, no adjustment to the carrying value of Friction Materials' assets was required based on a current reassessment of the fair value of those assets. Such reassessment of the fair value of the property, plant and equipment was performed using discounted estimated future cash flows of the business. The fair value approximated the written-down held for sale value and was also less than the carrying amount of the property, plant and equipment prior to being classified as held for sale, adjusted for depreciation expense that would have otherwise been recognized had these assets been classified as held and used (see Note 21 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data” for further discussion). We recognized asbestos related litigation charges of $1,548 million principally related to costs associated with the potential resolution of asbestos claims of NARCO (see Note 21 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data” for further discussion). We also recognized other charges consisting of customer claims and settlements of contract liabilities of $152 million and write-offs of receivables, inventories and other assets of $60 million. These other charges related mainly to our Advanced Circuits business, bankruptcy of a customer in our Aerospace reportable segment, and customer claims in our Aerospace and Automation and Control Solutions reportable segments. Additionally, we recognized other charges consisting of other probable and reasonably estimable environmental liabilities of $30 million and write-offs related to an other than temporary decline in the value of certain equity investments of $15 million.

      The following tables provide details of the pretax impact of total net repositioning and other charges by reportable segment.

Aerospace

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Net repositioning charge

     $ 5        $ 10        $ 15  
      

Customer claims and settlements of contract liabilities

       (10 )                 99  
      

Write-offs of receivables, inventories and other assets

                         21  
      

Investment impairment charges

                         11  
          
        
        
 
      

     $ (5 )      $ 10        $ 146  
          
        
        
 
      

                       

Automation and Control Solutions

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Net repositioning charge

     $ 15        $ (22 )      $ 131  
      

Other probable and reasonably estimable legal and
environmental liabilities

       13                    
      

Business impairment charges

                         22  
      

Customer claims and settlements of contract liabilities

                         42  
      

Write-offs of receivables, inventories and other assets

                         17  
          
        
        
 
      

     $ 28        $ (22 )      $ 212  
          
        
        
 

33


      

                       

Specialty Materials

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Net repositioning charge

     $ 36        $ 16        $ 167  
      

Other probable and reasonably estimable legal and
environmental liabilities

       9                   23  
      

Business impairment charges

       42                   763  
      

Customer claims and settlements of contract liabilities

                         11  
      

Write-offs of receivables, inventories and other assets

       3          2          12  
      

Investment impairment charges

                2           
          
        
        
 
      

     $ 90        $ 20        $ 976  
          
        
        
 
      

                       

Transportation Systems

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Net repositioning charge

        $ 26            $ 5          $ 26  
      

Asbestos related litigation charges, net of insurance

          120                         167  
      

Other probable and reasonably estimable legal and environmental liabilities

                       11             
      

Business impairment charges

                                  92  
      

Write-offs of receivables, inventories and other assets

          1                         10  
             
            
          
 
      

        $ 147            $ 16          $ 295  
             
            
          
 
      

                       

Corporate

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Net repositioning charge

        $ 6          $ 4        $ 38  
      

Asbestos related litigation charges, net of insurance

          (44 )                   1,381  
      

Other probable and reasonably estimable legal and environmental liabilities

          543            250          7  
      

Write-offs of receivables, inventories and other assets

          10                      
      

Investment impairment charges

                              4  
             
          
        
 
      

        $ 515          $ 254        $ 1,430  
             
          
        
 
      

                       

LIQUIDITY AND CAPITAL RESOURCES

Cash Flow Summary

      Our cash flows from operating, investing and financing activities, as reflected in the Consolidated Statement of Cash Flows, are summarized as follows:

      2004

  2003

  2002

      (Dollars in millions)
      

                       
      

Cash provided by (used for):

                       
      

Operating activities

     $ 2,253        $ 2,199        $ 2,380  
      

Investing activities

       (584 )        (680 )        (870 )
      

Financing activities

       (1,223 )        (895 )        (932 )
      

Effect of exchange rate changes on cash

       190          305          50  
          
        
        
 
      

Net increase in cash and cash equivalents

     $ 636        $ 929        $ 628  
          
        
        
 
      

                       

      Cash provided by operating activities increased by $54 million during 2004 compared with 2003 due primarily to increased cash earnings and a decrease in voluntary U.S. pension contributions of

34


$630 million. The increase in cash provided by operating activities was partially offset by an increase in net asbestos related liability payments of $558 million as the prior year included $472 million in cash received from Equitas related to a comprehensive policy buy-back settlement, and an increase in working capital (receivables, inventories and accounts payable), usage of $268 million principally related to higher sales and a weakening of the U.S. dollar versus the Euro and Canadian dollar throughout 2004. Cash provided by operating activities decreased by $181 million during 2003 compared with 2002 mainly due to a $540 million increase in voluntary U.S. pension contributions as well as an increase in working capital usage due primarily to a weakening of the U.S. dollar versus the Euro and Canadian dollar throughout 2003. The decrease was partially offset by reduced severance and exit costs payments of $247 million, lower litigation payments of $222 million, as well as insurance receipts in excess of asbestos liability payments of $107 million during 2003.

      Cash used for investing activities decreased by $96 million during 2004 compared with 2003 due primarily to an increase in proceeds from sales of businesses of $289 million largely from the dispositions of our Security Monitoring and VCSEL Optical Products businesses in the current year. Additionally, proceeds from the maturity of investment securities were $80 million in 2004. The decrease in cash used for investing activities was partially offset by an increase in spending for acquisitions of $185 million due principally to various acquisitions in our Automation and Control Solutions reportable segment and an investment of $115 million in auction rate securities. Cash used for investing activities decreased by $190 million during 2003 compared with 2002 due mainly to reduced spending of $321 million for acquisitions, principally reflecting the acquisition of Invensys in October 2002. The decrease was partially offset by reduced proceeds from sales of investments of $91 million related to the disposition of a cost investment in our Automation and Control Solutions reportable segment in 2002, and reduced proceeds from sales of businesses of $46 million. Proceeds from business sales in 2003 resulted from the sale of certain non-core Specialty Materials (Engineering Plastics, Rudolstadt and Metglas) and Aerospace (Honeywell Aerospace Defense Services) businesses.

      Cash used for financing activities increased by $328 million during 2004 compared with 2003 due primarily to an increase in repurchases of common stock of $687 million in connection with our stock repurchase program announced in November 2003 partially offset by a reduction in debt repayments, net of issuances, of $337 million in 2004. Total debt of $5,273 million at December 31, 2004 was $113 million, or 2 percent higher than at December 31, 2003 principally reflecting higher commercial paper borrowings to fund our share repurchases in 2004. Cash used for financing activities decreased by $37 million during 2003 compared with 2002 mainly due to lower net debt repayments in 2003, partially offset by cash used to repurchase shares in the fourth quarter of 2003. Total debt of $5,160 million at December 31, 2003 was $71 million, or 1 percent higher than at December 31, 2002 principally reflecting the assumption of $267 million of debt associated with the purchase of assets under operating leases partially offset by lower short-term borrowings.

      We had approximately $3.4 and $2.6 billion of cash and cash equivalents held by non-U.S. subsidiaries mainly in local currencies (principally the Euro, Canadian dollar, and Australian dollar) at December 31, 2004 and 2003, respectively. The $190 and $305 million increases in cash and cash equivalents in 2004 and 2003, respectively, due to exchange rate changes, principally resulted from a weakening of the U.S. dollar mainly against the Euro and Canadian dollar throughout 2004 and 2003. We manage our worldwide cash requirements considering available cash balances and the most cost effective method to access those cash balances. The repatriation of cash balances from some non-U.S. subsidiaries to the U.S. could have U.S. tax consequences (see discussion of American Jobs Creation Act of 2004 in Note 7 of Notes fo Financial Statements in “Item 8. Financial Statements and Supplementary Data”); however, substantially all cash balances held by non-U.S. subsidiaries are available without legal restrictions to fund business operations.

Liquidity

      We manage our businesses to maximize operating cash flows as the primary source of our liquidity. Operating cash flows were $2.3 billion in 2004. We have approximately $3.6 billion in cash and cash equivalents and $4.8 billion in working capital (receivables, inventories and accounts payable).

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Each of our businesses continues to focus on strategies to improve working capital turnover in 2005 to increase operating cash flows. Considering the current economic environment in which each of our businesses operate and our business plans and strategies, including our focus on growth, cost reduction and productivity initiatives, we believe that our cash balances and operating cash flows will remain our principal source of liquidity. In addition to our available cash and operating cash flows, additional sources of liquidity include committed credit lines, access to the public debt and equity markets using debt and equity securities, including commercial paper, as well as our ability to sell trade accounts receivables.

      A source of liquidity is our ability to issue short-term debt in the commercial paper market. Our ability to access the commercial paper market, and the related cost of these borrowings, is affected by the strength of our credit ratings and our $2.3 billion of committed bank revolving credit facilities (Revolving Credit Facilities). Our credit ratings are periodically reviewed by the major independent debt-rating agencies. In 2004, Standard and Poor's and Fitch Rating Services affirmed their corporate ratings on our long-term debt, A and A+, respectively, and short-term debt A-1 and F1, respectively, and revised Honeywell's outlook from “negative” to “stable”. Moody's Investors Service affirmed its corporate rating on our long-term and short-term debt of A2 and P-1, respectively. Our credit rating provided by Moody's Investors Service reflects a “negative outlook” due principally to the cyclical market conditions in the commercial air transport industry, our potential exposure to asbestos liabilities, and the existence of integration risk associated with our recently announced acquisition of Novar plc (expected to be completed in the first quarter of 2005). The “negative outlook” has not impaired, nor do we expect it to impair, our access to the commercial paper markets.

      Commercial paper notes are sold at a discount and have a maturity of not more than 270 days from date of issuance. Borrowings under the commercial paper program are available for general corporate purposes as well as for financing potential acquisitions. There was $220 million of commercial paper outstanding at December 31, 2004.

      Our $2.3 billion of Revolving Credit Facilities are maintained with a group of banks, arranged by Citigroup Global Markets Inc. and J.P. Morgan Securities Inc., and comprises: (a) a $1 billion Five-Year Credit Agreement and (b) a $1.3 billion Five-Year Credit Agreement. The credit agreements are maintained for general corporate purposes, including support for the issuance of commercial paper. The $1 billion Five-Year Credit Agreement was put in place on October 22, 2004, replacing a $1 billion 364-Day Credit Agreement which was expiring on November 24, 2004. This newly established Five-Year credit facility includes a $200 million sub-limit for the potential issuance of letters of credit. The $1.3 billion Five-Year Credit Agreement was increased in November 2003 with the addition of a $300 million sub-limit for the potential issuance of letters of credit. See Note 15 of Notes to Financial Statements in “Item 8. Financial Statements and Supplementary Data.”

      We also have a shelf registration statement filed with the Securities and Exchange Commission which allows us to issue up to $3 billion in debt securities, common stock and preferred stock that may be offered in one or more offerings on terms to be determined at the time of the offering. Net proceeds of any offering would be used for general corporate purposes, including repayment of existing indebtedness, capital expenditures and acquisitions.

      We also sell interests in designated pools of trade accounts receivables to third parties. The sold receivables were over-collateralized by $120 million at December 31, 2004 and we retain a subordinated interest in the pool of receivables representing that over-collateralization as well as an undivided interest in the balance of the receivables pools. New receivables are sold under the agreement as previously sold receivables are collected. The retained interests in the receivables are reflected at the amounts expected to be collected by us, and such carrying value approximates the fair value of our retained interests. The sold receivables were $500 million at both December 31, 2004 and 2003.

      In addition to our normal operating cash requirements, our principal future cash requirements will be to fund capital expenditures, debt repayments, employee benefit obligations, environmental remediation costs, asbestos claims, severance and exit costs related to repositioning actions, share repurchases and any strategic acquisitions. Our total capital expenditures in 2005 are currently projected at approximately $775 million. These expenditures are primarily intended for maintenance,

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