In smeltingSmelting furnaces, the degradation and failure of refractory linings are one of the primary causes of campaign termination and rebuilds. Unplanned failures result in molten material runouts and costly repairsRepair and shutdowns, which motivates operators to mitigate risk through operations and maintenance actions informed by inspection and monitoring. The loss of refractory thickness is often viewed as the main contributor to molten material runouts. However, equally important is the contribution from gap formation in a refractory lining. Maintaining a stable lining requires assessment and mitigation of multiple failure mechanisms. This paper explores the key mechanisms behind refractory deterioration and associated furnace integrity failure. It highlights how integrating data from periodic inspections and continuous monitoring systems can enable proactive measures, enhancing operational safety and reliability. Additionally, we demonstrate how such data-driven approaches contribute to optimizing refractory quality, improving procurement practices, extending refractory lining service life, and minimizing wasteWastes generation throughout the furnace’s operational lifecycle. These insights are vital for fostering safer, more efficient smeltingSmelting operations and achieving long-term sustainabilitySustainability goals.