The closed-loop control of a plasma-arc melting furnace was investigated. The different sub-processes were found to be highly coupled, and the available sensors and actuators were insufficient. Both of these factors increase the difficulty of controlling the process. A control system design is shown which combines groups of sensor readings by using the available knowledge about the process to generate new variables which are more directly relevant to the control of the system. This new information, even if not used in a control system, is useful to the operators. The benefits of closed-loop control are discussed