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The cheapest item on your list could halt the entire plant

Measuring supply risk by spend hides the real danger: cheap materials with no substitute, controlled by a handful of players, that can halt a line.

Brutalit newsroom · 5 min read
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In this article

    The biggest threat to a manufacturer's supply may sit on the cheapest line of its purchasing spreadsheet. That is the central conclusion of a Boston Consulting Group study on critical minerals published on October 27, 2026. The message, which applies to any company that depends on components, is that measuring risk by the size of the spend means looking in the wrong place.

    What happened

    BCG identified three blind spots that leave industrial companies exposed to critical mineral shortages. The first is giving too much weight to spend. Companies track high-volume, high-cost materials and overlook what the study calls "mosquito minerals," small in value and enormous in damage when they run short.

    The clearest example is gallium. The global market is worth less than US$350 million a year, with about 900 tons produced. Even so, roughly US$3.5 trillion in end products depend on it. Rare earths follow the same logic. By BCG's estimate, they account for about 40% of the cost of a magnet, but less than 1% of the total value of an electric car.

    The second blind spot is looking only at the direct supplier. Minerals arrive embedded in components and also show up in tools and production processes. The third is focusing on where a mineral is mined and losing sight of who processes it and who owns the assets. The study notes that China refines about 90% of rare earths.

    The backdrop is one of tightening supply. Under BCG's model, demand for key inputs is expected to reach 120% to 250% of projected supply by 2040.

    Why it matters

    Beyond risk, there is money left on the table. Public funding commitments for critical minerals in advanced economies reached about US$65 billion in 2025, more than four times the 2023 level, according to figures cited by BCG. Even so, some countries have spent less than 10% of the capital set aside. Access to these funds usually requires long-term offtake contracts, and that commitment is credible only for companies that know their own exposure.

    A company that cannot see its own exposure therefore falls behind twice. It risks shutting down and cannot tap the support that exists to prevent it.

    What changes for you

    For owners and boards, the discussion about exposure needs to reach concrete answers about where it lies, how much it is worth and how fast the company can respond. The study cites a company that, by mapping its material flows, found US$5 billion in value at risk across more than 15 commodities that did not appear in any purchasing data. A number like that changes investment priorities.

    For sales leaders, input shortages turn into missed delivery dates and contracts that do not get renewed. Knowing in advance which product lines depend on concentrated materials makes it possible to negotiate realistic lead times and protect the most valuable customers.

    For those who run operations, the job is to go down the chain: component, subcomponent, process and origin. Qualifying an alternative supplier takes time, and that time has to be built into the plan before the crisis.

    What changes in Brazil

    In Brazilian plants, the distance to the source of the material tends to be greater. It is common to buy finished components, often imported, and each additional intermediary deepens the direct-supplier blind spot.

    There is also room to play offense. If major economies are setting aside capital to diversify supply and requiring long-term contracts, Brazilian companies that know their own supply chains can negotiate better, as buyers or as an alternative outside the concentrated hubs. The BCG study does not look at Brazil, and the application here follows from the logic it describes.

    The play

    1. Rebuild your risk map around dependence, not spend. List the materials with no quick substitute and few suppliers, even if they are cheap. Those are the candidates to halt operations.

    2. Separate cost from availability. The study recommends asking whether each move addresses price or a shortage of material. For shortages, the options range from qualifying an alternative supplier before you need one, strategic inventory and long-term offtake contracts to product redesign, material recovery (circularity) or greater control over supply.

    3. Take the issue to the executive team. BCG argues that the CEO and the executive team should lead this work. Decisions on inventory, redesign and long-term contracts affect cash and margins and go beyond the remit of purchasing.

    The other side

    The study comes from a consulting firm that sells this kind of diagnosis, and that deserves to be taken into account. The demand figures through 2040 come from a proprietary model with assumptions readers cannot fully verify. Long-range forecasts on electrification, artificial intelligence and defense can miss in either direction.

    The text itself warns against overreach. One is poorly executed diversification that merely swaps one concentrated supplier for another. Another is buying suppliers at the source when the analysis does not justify it. And there is excessive insurance, which ties up cash unnecessarily. For a midsize company, mapping the entire chain takes time and money. The sensible path is to start with the products that weigh most on revenue and the materials with no alternative, and only then expand.

    What to watch

    • New export restrictions on niche minerals and their effect on the prices of imported components.
    • Calls for public critical-mineral funds that require long-term offtake contracts as a condition of access.
    • Component suppliers starting to pass supply risk on through lead times and prices.

    Questions to take to the meeting

    Do we know which materials, even cheap ones, could halt our production?

    If the list was built from purchasing spend, probably not. Each component needs to be cross-checked against the material it contains and where that material comes from.

    Does our risk map go beyond the direct supplier?

    The study shows that exposure hides inside components, tools and processing steps. Without looking below the first tier, the map is incomplete.

    Are we treating scarcity as a price problem or an availability problem?

    They call for different responses. Price can be negotiated, while a material shortage requires a qualified alternative supplier, strategic inventory, product redesign, circularity or greater control over supply.

    Sources
    1. Why Critical Mineral Shortages Are a CEO Issue · Boston Consulting Group
    2. Three Blind Spots Leave Industrial Companies Exposed to Critical Mineral Shortages · Boston Consulting Group
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