The answer it seems may not be good. Intel’s Q3 results are only half of the news today; the other half of that news is Intel’s projections and planned actions for Q4. Intel has taken an unusually conservative stance on Q4, projecting that both revenue and their all-important gross margin will be down in Q4 of 2012 as compared to 2011. Specifically, Intel is projecting that their gross margin will be 57%, as compared to their incredible 65.5% gross margin from last year. On a quarterly or even yearly basis this would be a major shift for Intel, and it is a strong indicator that the weakness in the PC market will hurt Intel by more than just reducing their net income a bit like what happened in Q3.
This brings us to Intel’s unexpected revelation during their earnings call and the primary reason we're covering this: idle fabs and inventory buildups. Due to a buildup in inventory and a desire to prevent further buildup in what Intel is projecting to be a weak quarter, Intel will be taking the unusual step of letting quite a bit of fab capacity go idle. For Q4 Intel’s fab utilization will be sub-50%, with that being a combination of capacity idled to keep supply down and another fraction idled for the upgrade to 14nm. Because Intel would rather have too much capacity than too little they routinely take fab capacity idle for both production purposes and upgrade purposes – i.e. the 14nm downtime would need to happen regardless – but it’s very rare for Intel to let utilization fall below 50% like this.
Rolling this back into Intel’s finances, Intel’s incredible gross margins hinge on running their fabs at as close to full capacity as possible. So while idle fab capacity is still better than an inventory glut (or price cuts), it’s not without consequences. The consequences being Intel’s relatively low gross margin forecast for Q4, which if it comes true would be Intel’s lowest gross margin since 2009 at the end of the recession.
On that note, perhaps the cruelest part of this is that because Intel’s overcapacity appears to be at 22nm – Intel’s standing inventory is nearly 70% Ivy Bridge – Intel’s options are to produce Ivy Bridge or go idle. Atom is still built on Intel’s older 32nm process, so even if Intel is in a position to capitalize on the strong mobile market they can’t shift from producing PC CPUs to mobile SoCs. In a situation like this Intel’s accelerated Atom roadmap can’t come soon enough