Facility layout optimization is very essential to enhance material flow, minimize operation expenses, and maximize the efficiency of the manufacturing process. The absence of efficient layouts in most Egyptian industries causes unnecessary flows of materials and inactive transportation, which generates losses in efficiency above 35 percent. This work presents and checks the effectiveness of a genetic algorithm procedure to link workstation layouts with feasible material flows in terms of cost considerations: material handling cost, rearrangement cost, and fixed operational cost. The model uses elitist selection operators with edge recombination crossover and two-point swap mutation to reduce total cost. The proposed approach was validated in a real case study conducted in a metal working and assembly plant with twenty workstations. The obtained near-optimal solution was: [11,10,8,9,17,12,1,7,13,15,2,5,4,19,16,14,6,3,0,18] with the total cost of 13,640 units. The results validated in FlexSim 2021 showed good correlation between calculated and simulated values with clear efficiency in terms of throughput, travel distances, and process efficiency. The new models achieved better results in comparisons with previously designed models based on the genetic algorithm method, validating the proposed solution.