Facility layout problem is crucial in the design of manufacturing systems across industries due to its significant economic implications and considerable impact on various decision criteria, including safety considerations in industries like casting. The presence of hazardous equipment, such as furnaces and melt casting units, necessitates layouts that mitigate safety risks effectively. This research develops a model that optimizes both transportation costs and safety risks concurrently. To achieve this, we introduce a multi-objective programming model specifically designed for addressing unequal area layouts. The proposed nonlinear model is converted into a linear equivalent to facilitate solution finding. We employ the NSGA-II algorithm to generate non-dominated Pareto solutions, which is further refined through the Taguchi method for optimal parameter settings. Additionally, goal programming is utilized to extract a single solution from the Pareto set. Empirical validation is performed using real-world data from a casting workshop, revealing objective function values in goal programming of 4253, 20, and 495—closely aligning with the solutions derived from the NSGA-II algorithm. The results demonstrate the model\\\\\\\'s practicality and effectiveness in real-world applications.

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