This article proposes qualitative research to reduce fouling noise created by a specific component in an alternator. The three major problematic stages in the manufacturing process of an alternator such as forming, winding, and varnishing are monitored and necessary corrective action has been implemented. The different characteristics of these stages namely top tool diameter, preheating, rpm, etc were examined. “Shainin Design Of Experiments“ (DOE) technique was used to deeply analyze the alternator. The traditional method of analyzing quality issues was the Taguchi DOE methodology. The rejection ratio was formulated to identify the reason for noise occurring in a component. A wedge paper protrusion was found to be present in the stator of an alternator. The issue is rectified by placing a nominal gap between the stator and the opposite surface. The efficiency of the alternator was found to be increased to a greater extent and also the number of rejections in an alternator due to fouling noise has been reduced.

Forming, Fouling noise, Shainin DOE, Stator, Varnishing, Wedge paper, Winding.