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Sonal OrvelkarChief Operating Officer · Essays & perspective

Sonal Orvelkar · Chief Operating Officer · India

From paper-component preparation to the whole receiving sequence

APPOINTMENT 1 / Jan 2023 — Present

Chief Operating Officer

Zerqavi Transit Materials

Sector
Paper-honeycomb transit protection and reusable industrial dunnage
Ownership
Regional industrial investor 47%, working founders 38%, employee trust 15%
Company scale
FY2026 revenue ₹168 crore; operating profit ₹18.6 crore
Employees
480 employees
Geography
Chhatrapati Sambhajinagar headquarters and manufacturing; second site in Satara
Reporting to
CEO Meena Talverhi
Team
330 operations colleagues through five managers
Financial scope
₹79 crore annual operating expense; ₹6.4 crore approved capital expenditure

Mandate

Make material condition, kit identity and technically released availability visible across the operating sequence

Outcomes

  • Funded storage and handling work after a defined panel-condition review
  • Changed kit segregation rather than rely only on a final checklist
  • Separated returned, held, repaired and retired dunnage
  • Matched preparation quantities more closely to the authorised usable window

Decisions in context

The COO appointment brought responsibility for 330 operations colleagues through five managers, with ₹79 crore annual expense and ₹6.4 crore approved capital expenditure. I report to CEO Meena Talverhi. The company has 480 employees and recorded ₹168 crore revenue and ₹18.6 crore operating profit in FY2026. Quality head Rafiq Neshvali reports separately to the CEO, preserving the authority of qualified teams over specifications and release. My decisions concern the resources and sequence that allow material to reach the next user in an acceptable condition. The recent cases required spending on storage, kit preparation, return inspection and smaller adhesive batches instead of accepting convenient counts as a complete operating result. I have no statutory directorship. In preparing for a first board opportunity, I would translate these experiences into questions about enterprise assumptions while leaving technical and operating decisions with their responsible owners.

Reason for the move

Current operating role; considering a first non-executive seat

APPOINTMENT 2 / Sept 2017 — Dec 2022

Vice President, Operations

Zerqavi Transit Materials

Sector
Industrial transit protection and reusable packing support
Ownership
Private company with regional-investor, founder and employee-trust interests
Company scale
FY2017 revenue ₹119 crore
Employees
365 employees at entry
Geography
Two-site operations in Maharashtra
Reporting to
Chief Executive Officer
Team
250 operations colleagues through four managers
Financial scope
₹53 crore annual operating expense; ₹4.1 crore approved capital expenditure

Mandate

Connect two-site preparation and customer returns through a clear account of material condition

Outcomes

  • Examined what common item descriptions omitted about condition
  • Connected receiving responsibility with earlier preparation and handling
  • Developed managers able to distinguish physical stock from released stock

Decisions in context

I joined Zerqavi in September 2017 for a two-site remit. The company employed 365 people and recorded ₹119 crore revenue in FY2017. I led 250 operations colleagues through four managers, with ₹53 crore annual expense and ₹4.1 crore approved capital expenditure. A shared item description made coordination easier, but it could also conceal differences in the condition or revision of what each site held. I wanted the receiving team to know more than the quantity being transferred. Customer returns raised the same issue in another form: material could be physically present without being ready for another use. The work required planning, quality and commercial colleagues to use compatible categories while retaining their different responsibilities. The COO promotion broadened the operating account and the investment choices attached to it, rather than change the technical authority required for acceptance.

Reason for the move

Promoted to COO

APPOINTMENT 3 / Apr 2011 — Aug 2017

Plant Head

Belqora Transit Packs

Sector
Customer-specific industrial transit packaging
Ownership
Privately owned regional manufacturer
Company scale
FY2011 revenue ₹67 crore
Employees
230 employees
Geography
Western Maharashtra plant and regional industrial customers
Reporting to
Managing Director
Team
180 operations colleagues through four managers
Financial scope
₹31 crore annual operating expense; ₹2.8 crore approved capital expenditure

Mandate

Connect component production with the configuration the customer expected to receive

Outcomes

  • Examined assembled-kit identity alongside individual component records
  • Connected revision changes with stock already made
  • Developed a plant-level account of preparation and dispatch responsibility

Decisions in context

Belqora gave me responsibility for a plant rather than one production department. It employed 230 people and recorded ₹67 crore revenue in FY2011. I led 180 operations colleagues through four managers, with ₹31 crore annual expense and ₹2.8 crore approved capital expenditure. Customer-specific packing work made it clear that individually acceptable components were not enough. The assembled kit had to correspond to the intended configuration, including the revision applicable to that order. I learned to ask what happened to stock already made when a drawing changed and how the picking team recognised the combination it needed. Those questions linked engineering records with physical preparation. The subsequent Zerqavi opportunity appealed because it extended that problem across two sites and a returnable-material system, where the receiving operation needed a reliable account of both identity and condition.

Reason for the move

Recruited to Zerqavi for a broader two-site role

APPOINTMENT 4 / Oct 2004 — Mar 2011

Production Manager

Dorzheni Paper Components

Sector
Converted paper components for industrial applications
Ownership
Founder-family-owned regional private company
Company scale
FY2004 revenue ₹36 crore
Employees
175 employees
Geography
Nashik and regional industrial customers
Reporting to
Plant Head
Team
Sixty-eight colleagues through three supervisors
Financial scope
₹8.9 crore annual operating expense; ₹64 lakh approved capital expenditure

Mandate

Make preparation, storage and production sequence work as one operating account

Outcomes

  • Examined the waiting time created by production plans
  • Connected local batch convenience with the next process's requirements
  • Completed a part-time packaging-operations diploma

Decisions in context

Promotion in October 2004 made me responsible for sixty-eight colleagues through three supervisors. Dorzheni employed 175 people and recorded ₹36 crore revenue in FY2004. My remit carried ₹8.9 crore annual expense and ₹64 lakh approved capital expenditure. The difficult choices concerned the sequence around production as much as the production operation itself. A larger batch could reduce local preparation while leaving material waiting longer elsewhere. I began to ask whether the next process could use what our preferred sequence produced, under the conditions it actually faced. A part-time packaging-operations diploma at Qorzemi Materials Institute, completed in November 2009, helped me examine those relationships more systematically. The Belqora move offered responsibility for the whole plant, including the coordination problems I had previously encountered from only one department's position.

Reason for the move

Joined Belqora for a first plant-head appointment

APPOINTMENT 5 / Jul 1998 — Sept 2004

Production Engineer

Dorzheni Paper Components

Sector
Regional paper-component conversion
Ownership
Founder-family-owned private business
Company scale
FY1998 revenue ₹14.8 crore
Employees
Ninety-two employees
Geography
Nashik
Reporting to
Production Engineering Manager
Team
Member of a six-person engineering group; no direct reports
Financial scope
No independent spending or hiring authority

Mandate

Learn the relationship between processing, waiting and the condition received by the next operation

Outcomes

  • Observed handling and waiting alongside machine operations
  • Supported investigations under experienced engineering and quality colleagues
  • Developed the practical knowledge used in a later production-management remit

Decisions in context

I joined Dorzheni in July 1998, two months after completing production engineering. The company employed ninety-two people and recorded ₹14.8 crore revenue in FY1998. I worked in a six-person engineering group under a production engineering manager, without direct reports or independent expense authority. My early work taught me to follow the component after the point at which our own operation had been recorded as complete. Handling and waiting could change what the next colleague received. Experienced engineers and quality colleagues helped me distinguish an observation from an accepted explanation, and a proposed change from an authorised one. I learned to ask for the sequence around a problem before attributing it to the machine. Production management later gave me responsibility for that sequence and for the people and resources needed to make it work.

Reason for the move

Promoted to production manager

What I am looking for next

I plan to remain in operating leadership while considering one first non-executive appointment in an industrial business. My contribution would concern the assumptions behind availability, product readiness and reuse, especially where a company reports a convenient count that conceals further work. I would not seek a seat in order to choose another factory's storage layout or override its quality team. I have no current directorship, and twenty annual days is a provisional allowance beyond my employment. Employer consent, the calendar and relationships with Zerqavi would need examination. I passed the databank proficiency assessment in June 2026 within this fictional career, but that does not settle independence or suitability for a particular company. I would look for a chair who values operational questions alongside financial and legal expertise. Induction should help me understand the prospective company's products and obligations before applying a lesson drawn from paper-based transit protection to a different industrial setting.