Working with molten metal has always been and will always be a dangerous workplace. No matter how carefully equipment is designed, workers are trained and procedures are followed, the possibility of an accident can occur in melting workplace. Some primary causes of melt splash and furnace eruptions include wet or damp charge material, dropping heavy charge into a molten bath, wet or damp tools or additives and sealed scrap or centrifugally cast scrap rolls. Induction melting brings together three things (water, molted metal and electricity) that have the potential for concern if the furnace is not properly working. Induction furnace must have a water cooling system built into the coil itself. Water picks up the heat caused by the current as well as heat conducted from the metal through the refractory. The water carries the heat to a heat exchange for removal. Spill pits serve to contain any molten metal spilled as a result of accident, run out or dumping of the furnace in an emergency. If a leak is suspected at any time, cease operation and clear the melt deck area of all personnel and empty the furnace. Molten metal fins can penetrate worn or damaged refractory and come into contact with the coil. A furnace or a close capture hood which suddenly swings down from a tilted position will cause injury or death. Whenever workers are working on a furnace or close capture hood when it is in the tilted position, be sure that it is supported with a structural brace that is strong enough to keep it from dropping if hydraulic pressure is lost. In theory refractory wear should be uniform, however, in practice this never occurs. The most causes of lining failure are improper installation of refractory material, inadequate sintering of refractory material, failure to monitor and record normal lining wear, allowing the lining to become too thin, installation of the wrong refractory, improper preheating of a used cold lining, failure to properly maintain the furnace the sudden or cumulative effects of physical shocks or mechanical stress, and excessive slag or dross buildup. Pouring cradles provide bottom support for crucibles. A crack in the crucible occur below the bottom ring support, the bottom of the crucible can drop and molten metal will spill and splash, possibly causing serious injury or death. To reduce this danger, a pouring cradle that provides bottom support for the crucible must be used. Power supply units must have safety locks and interlocks on all doors and access panels. Workers who work with low voltage devices must be made aware of the risk posed by high levels of voltage and current. The most causes of accidents are introduction of wet or damp material, improper attention to charging, failure to stand behind safety lines, coming into contact with electrically charged components and lack of operator skills and training. Only trained and qualified personnel are to have access to high risk areas. Safety lockout systems are another effective measure to prevent electrical shock

To prevent safety hazards in dangerous working area, we have proposed an intelligent image analysis system. Six common patterns of safety violations of workers’ are defined and its motion detection algorithms are developed for alarm to CCTV　monitoring system. Developed algorithms are implemented at 195 dangerous areas such as chemical and gas treated room. The results of violated motion detection ratio by developed system shows 94.95% of true positive cases, and 0.21% of false positive cases from all 587,645 event cases in one month implementation period. In the period, it is observed that the number of safety rule violations and the following accidents are decreased.