Dielectric Failures Reduction in the Main Stator Cell: A Mechanical and Process Engineering Approach

Abstract

Dielectric failures account for approximately 65% of total defects in the Main Stator Cell of an aerospace manufacturing facility. This study identifies mechanical interaction during manual forming operations as the primary root cause, rather than purely electrical phenomena. Contact mechanics analysis using the Hertzian model reveals that conventional steel pliers generate contact pressures of approximately 1.10 GPa, far exceeding enamel insulation tolerance. A dedicated Delrin forming tool reduces contact pressure by 99.5%, friction forces by 75%, and bending stress by 75.2%. Complementary process improvements—including standard work updates, dedicated dielectric test operations, and operator training—achieved a 37% reduction in Scrap, Rework, and Repair (SRR) costs and a 30% reduction in Parts Per Million (PPM) defect rate, surpassing the established 35% SRR target.