In industrial manufacturing environments, particularly in the plastic furniture sector, workers involved in manual material handling are frequently exposed to ergonomic risks. These include awkward postures, repetitive movements, and physically demanding tasks that can contribute to work-related musculoskeletal disorders (WMSDs). This study was conducted at a small-scale plastic manufacturing facility, with the aim of identifying ergonomic hazards in a tray production line and proposing improvements to enhance worker safety and productivity. Data collection involved direct observation of manual tasks and a structured survey to understand discomfort levels and task perceptions. Simulation-based analysis using Digital Human Modeling (DHM) in Siemens Tecnomatix JACK software was also carried out analysing the posture. Postural risk was quantified using the Rapid Upper Limb Assessment (RULA) tool which is integrated within JACK. Risk involved manual tasks such as raw material transfer, container lifting, and product collection were modeled and analyzed in detail. The results showed high RULA scores for postures like container lifting, bending which involves severe postural risks. Survey responses validated these findings, revealing a high prevalence of discomfort in the lower back, shoulders, and wrists among workers. Based on these insights, the study proposes several recommendations including workstation redesign, use of mechanical aids, task rotation, and ergonomic training programs. These interventions aim to reduce physical strain, improve postural alignment, and promote safer working conditions.