Improper working techniques and substandard assistive device usage during manual transportation of heavy plastic rolls from storage to extrusion machine expose workstation operators to occupational health risks in a plastic manufacturing factory. This study focuses on the redesign the existing manual lift table to improve the plastic roll handling process. The procedure was initiated with a workplace observation followed by a questionnaire survey among nineteen operators. The ergonomic risk level was analysed through Rapid Upper Limb Assessment (RULA). The improved design concept of the device was constructed and selected using House of Quality (HOQ) and Pugh method. Statistical analysis from the survey revealed that most operators experienced occasional discomfort (36.0%) at similar pain level (44.3%) at wrist/hands, upper back, lower back, and shoulder mainly caused by difficulty to transfer the plastic rolls using the existing device. This study concluded that the new design of the plastic roll handling device is able to improve plastic roll handling process with the largest RULA score improvement from 7 to 2. Actual fabrication of new design and application should be implemented in order to improve the work posture and reduce the exertion of excessive force.