From Manual Processes to Lean, Digital and Sustainable Operations

LEAN BUSINESS OF THE YEAR — FINALIST 2024
Palm Free Irish Soap

How a family-run soap producer doubled output per person by combining lean thinking with practical digital systems

98%

Increase in output per person

2 → 1

Locations consolidated

Digital

Order, stock & traceability systems

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The Business

Palm Free Irish Soap is a family-run business producing natural, organic soap products. The business serves both B2B and B2C customers across Ireland, with a growing reputation for quality, sustainability, and ethical production.

Sector: Natural soap & skincare production

Location: B2B and B2C across Ireland

Type: Family-run SME

The Challenge

As the business grew, operations became increasingly inefficient. Production and packing were split across two locations, creating unnecessary transport, duplication, and coordination overhead. Core processes still relied on paper and manual systems.

The business was dealing with:

  • Production and packing split across two separate locations
  • Heavy reliance on paper-based systems for orders and stock
  • Manual order entry creating delays and errors
  • Limited visibility of stock levels, order status, and workflow


The key challenge: How to simplify operations, improve efficiency, and support growth — without adding complexity or compromising on the business’s sustainable values.

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What We Did

We worked with the business over several years to gradually improve how they operate, combining lean thinking with practical digital systems — one step at a time.

  • Consolidated production into a single, more efficient location — reducing transport, energy use, and coordination overhead
  • Designed a lean production layout to reduce waste and improve flow
  • Replaced manual paper orders with a digital order portal, eliminating delays and errors
  • Introduced live order tracking and visual management across the operation
  • Implemented digital stock control with real-time visibility and automated reordering
  • Built batch traceability into the production process
Simple, practical improvements that make the business easier to run — and more sustainable to grow.

The Results

The combined impact of lean and digital improvements has been significant across the entire operation:

98% increase in output per person (2020–2024)

Major reduction in manual admin and paperwork

Faster and more accurate order processing with fewer errors

Improved stock control and full batch traceability

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Operational improvements

Orders processed digitally with full visibility of status and workload

Production follows a streamlined, efficient single-site flow

Staff have clear visibility and the business operates with less stress and more control

Sustainability impact

Reduced transport and energy usage by consolidating from two locations to one

Sustainable practices introduced across packaging and production

Lean and digital thinking now embedded in day-to-day operations

Recognition

★ Lean Business Awards — Finalist (Micro) — 2024

“LeanBPI helped us move from paper-based systems to digital solutions across ordering, packaging and production. The result is a more efficient operation, with less paperwork, fewer errors, and full accountability.” Tony Hoynes — Managing Director, Palm Free Irish Soap
LeanBPI

We help small businesses fix inefficient processes, implement the right systems, and take practical steps into process automation and AI.

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Limerick Ireland

(+353) 87 7444887

johnoshanahan@leanbpi.ie

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