Ergonomics plays a crucial role in cotton cultivation resulting in musculoskeletal complaints from cotton growers. Most operations like land preparation, sowing, intercultural, and cotton harvesting are done manually in Eastern India. Due to higher labour costs and lower returns, rice growers are now going for the cotton crop cultivated in the western Undulating Zone of Odisha. Improved machines and tools can minimize the risk of musculoskeletal injuries/complaints. The RULA and REBA techniques were used to evaluate the postural discomfort of workers. There were high ratings of discomfort in the arms, lower back, buttocks, shoulders, and neck. Physiological measures including energy expenditure rate (EER), oxygen consumption rate (OCR), and working heart rate (WHR) were measured, the WHR was observed at 138 beats min−1 for ridge and furrow making followed by 133 beats min−1 for sowing, then 135 beats min−1 for weeding and 128 beats min−1 for harvesting. Sowing is the most discomforting operation, exhibiting the highest discomfort ratings and energy demands, compounded by its traditional integration with field preparation in cotton cultivation of Odisha. To improve efficiency and reduce drudgery and fatigue in cotton cultivation, demonstration and proper training with improved sowing equipment are recommended for cotton farmers.