No more new zones for Karnataka please. Enough zones are there to trouble Kannadigas.
Simple solution should be:
1. Attach SR areas of Karnataka (in and around Mangalore) to SWR Mysore division or to KR Karwar division.
2....
more... Attach SWR areas of Goa state (VSG MAO, MAO Kulem) to KR Ratnagiri division.
Your suggestion of new zone with HQ at MAO is impossible as it's jurisdiction will become unmanageable as it will be from Mumbai to Kanyakumari!!!