Sunny Singh

Head of Digital, MVC @ Polycab India Limited

About

Focus - AI in Manufacturing, Industrial Analytics, Digital twins, Predictive maintenance, OT/IT convergence. My current work also focuses on scaling Industry 4.0 and digital manufacturing strategies that reduce fixed costs, increase asset uptime, and generate strong business impact. At Tata Steel and Indorama Ventures, I’ve delivered more than $400M in recurring savings via intelligent automation, MES, APM, GenAI, Digital Twin, and advanced analytics programs. While working for the Kalinga Nagar project(largest greenfield site in India) associated with Tata Steel, I have excelled in the management roles and streamlined operations of the Iron Making division(Blast Furnace, Coke & Sinter) producing 3.24 MTPA. I have won several accolades for my contributions to the industry, including the Tata Innovista Award and Apex-level recognition for process optimization and Safety Initiatives. Core Skills : Overall experience span across Design & Engineering, Commissioning, O&M, Process control in the manufacturing (metals, mining, oil & gas, , energy, chemical) sector. Smart Manufacturing Strategy | MES, ERP, APM | IIoT | Enterprise Data Infrastructure | Predictive Analytics | OT/IT Integration | Industrial AI/ML | Process Reliability | Energy Efficiency | Change Leadership | Digital Twin | GenAI | SIRI Assessment

Country

City

India

Industry

Consumer Goods

Skill

Internet of Things (IoT), Software Systems, Control System, SAP ERP, Industry 4.0, Artificial Intelligence (AI), Problem Solving, System Architecture, PCS7, Distributed Control System (DCS), Supply Chain Management, Operations Improvement, Digital Strategy, Automation, SCADA, Programmable Logic Controller (PLC), Electricity, Power Plants, Commissioning Support, Medium Voltage

Experience

Head of Digital, MVC

Polycab India Limited

2026-1 - Present · 9 mos

India

Leading digital transformation for Polycab Mfg sites(28 units) — margin expansion + working capital + risk reduction program.

General Mgr,Digital Transformation

Indorama Ventures

2022-6 - 2025-12 · 3 yrs 7 mos

Europe

APM, cloud-based analytics and reliability programs delivering uptime & energy gains (~10–20%). Leading global data integration framework (UNS + Edge + PI + Azure) across OT-IT for KPI visibility and GenAI enablement. Data Governance Task Force (Ops, IT, OT), driving “single source of truth” for plant KPIs. 🔹 Key Tools/Platforms: Honeywell APM, AVEVA PI, OSIsoft, SeeQ, Ignition UNS, SAP S/4HANA, Power BI

Project Manager/Senior Manager

Tata Steel

2012-1 - 2022-5 · 10 yrs 5 mos

Kalinganagar,Odisha

Design & Engineering, Commissioning, Operation, and Maintenance management for a globally integrated steel company with assignments across Digital Solution Implementation, Manufacturing Execution Systems, Cost & Asset Management for Energy & Utilities, Engineering, Maintenance, and Projects. •Led Iron Making Projects (BF, Coke & Sinter) completion and stabilization in a green field setup. •Led EBITDA improvement programs across diverse verticals viz. Energy efficiency, Procurement, Production, and Maintenance. •Led MARVEL Project management council(Iron making division). This contributed to TSK being the first Indian manufacturing plant to be included in the WEF’s Global Lighthouse Network. •Reduced OPEX by 3.2 Mn USD through a Reliability Enhancement Program with KPIs targeted to improve Energy Efficiency (CDQ power plant, Byproduct process), Process Yield, and Employee Productivity. •10X increase in MTBF with an OEE of (>98%) through strategic outsourcing & partnerships leading to a reduction in OPEX by 4.5 MN USD. •Optimized energy and water rate by 1.5% through the implementation of machine learning models across process units. •Formulation of ABPs and Long-term Plans for New Product development, Value in Use analysis, and Process efficiency analysis. •Increase asset utilization through digital initiatives structured around with the vision of a Single Process flow facility for increasing asset utilization.

Manager

Tata Steel

2010-7 - 2011-12 · 1 yr 6 mos

Jamshedpur, Jharkhand, India

Tata Steel Jamshedpur- Total Quality Management (TQM)-March’11 to Dec’11 •Member of Business Performance Excellence task-force to increase EBITDA (20%) of Tata Steel Group across diverse verticals viz. Energy efficiency, Procurement, Production, Maintenance, HR and general administration. •Formulation of ABPs and Long-term Plans for New Product development, Value in Use analysis, Process efficiency analysis for the council approval. •Facilitation for Long-product division of the company for preparation of DGP (Deming Grand Prize) which Tata Steel won in 2012(after achieving Deming Application Prize-2011). •Compilation and analysis of DM (Daily management) assessment scores on periodic intervals for tracking of weak areas and its strengthening. TSJ- Steel Melting Shop (LD#1)-July’10 to March’11 •Project Title – SHIKHAR, LONG PRODUCTS Led a project to enhance the accuracy of Torch cutting machine used for Billets in CC#1,2,3. This project increased the precision of cutting system and reduced the rejection of billets by customers due to quality issue(dimension & related issues),