Automated Spare Parts Supply for BVG: Smart Parcel Stations in Action
Maintaining the tram fleet of Berliner Verkehrsbetriebe (BVG) requires fast and error-free spare parts supply. Learn how TIKI SHARE, together with Alstom, DAHER and C+P Möbelsysteme, delivered a fully automated, SAP-integrated solution across three depots.
Book Demo
Previous processes were often shaped by manual handovers, paper delivery notes and time dependencies. The central challenges were:
Limited Availability
Spare parts must be accessible to technicians 24/7, independent of the opening hours of a central warehouse.
Lack of Traceability
Every withdrawal must be fully documented and assigned to the corresponding service order.
Complex System Integration
The solution had to integrate seamlessly into Alstom's existing SAP infrastructure to process orders (ORDRSP) and delivery notes (DESADV) automatically.
Error Susceptibility
Wrong deliveries to the wrong depot or unauthorized withdrawals had to be technically excluded.
The Solution: TIKI SHARE Smart Parcel Stations
To master these challenges, a system of intelligent locker installations (smart lockers) was implemented, combining hardware from C+P Möbelsysteme with the TIKI SHARE IoT platform.
Hardware Setup at the Depots
Custom locker systems were installed at the three BVG depots Marzahn, Lichtenberg and Weißensee. The systems offer compartments in various sizes — from small sensors to large mechanical components. Operation runs through a central terminal with touchscreen and scanner.
Seamless SAP Integration
The heart of the solution is the deep integration into Alstom's SAP system. The process runs fully automated: a BVG employee orders a spare part, Alstom checks availability and sends an order confirmation (ORDRSP IDoc) to the TIKI SHARE platform.
Storage by Logistics Provider
The logistics provider (DAHER) scans the delivery note barcode at the parcel station terminal. The system checks whether the delivery is intended for this specific depot. If so, a suitable compartment opens automatically.
Withdrawal by Technicians
The BVG technician authenticates via RFID badge or scans the order barcode. The system opens exactly the compartment containing the requested spare part.
Three Depots, One Continuous Process
The systems were installed one after another at the Marzahn, Lichtenberg and Weißensee depots. Before the first go-live, the SAP connection was validated with test orders so that order confirmations and delivery notes were processed cleanly from day one.
Four partners were involved with a clear division of roles: Alstom as system partner on the SAP side, DAHER for logistics, C+P Möbelsysteme for the cabinet systems and TIKI SHARE for control, platform and integration. Instructing technicians and logistics staff came down to a badge or a barcode scan.
Intelligent Error Prevention (Poka-Yoke)
The system is designed to proactively catch human errors.
Wrong Depot
If the logistics provider scans a package destined for Marzahn at the Lichtenberg station, the system refuses acceptance with the message "Delivery wrong depot".
Timeout
If a compartment is not closed within a defined time (e.g. 30 minutes) after opening, the system generates an alarm.
Unreadable Barcodes
For damaged labels, the order number can be entered manually as a fallback via the touch terminal.
Results and Value for BVG
The introduction of the smart parcel stations has fundamentally transformed spare parts supply.
24/7 Availability
Technicians can pick up required parts at any time, significantly reducing tram downtime.
Complete Documentation
Every storage and withdrawal is digitally recorded and reported back to Alstom's SAP system in real time. Shrinkage and search times have been drastically reduced.
Process Reliability
Automatic validation of deliveries and withdrawals virtually eliminates mix-ups.
Scalability
The cloud-based architecture of TIKI SHARE allows the system to be expanded with additional stations or depots at any time.
Related Solutions and Technologies
Transport & Infrastructure
Applications for depots, workshops and transit hubs.
Intelligent Locker Systems
Learn more about the hardware foundation of our smart lockers.
Locker Management Software
Discover the TIKI SHARE platform that enables SAP integration.
RFID Technology
How secure technician identification at the terminal works.
IDoc (SAP)
Background on the SAP data format ORDRSP and DESADV.
Poka-Yoke
The principle of error prevention in logistics automation.
Frequently Asked Questions
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