An alternator, which converts mechanical rotational energy into electrical energy, is an important component of a vehicle. Alternators operate over a broad range of rotational speeds, typically from 3,000 RPM to 18,000 RPM, which demands a cooling fan producing sufficient airflow, ideally with a minimum of noise. In the current study, an optimized alternator-cooling fan was developed through a linked DOE(Design OF Experiment) process and numerical analysis. The SC/Tetra and FlowNoise S/W programs were used to calculate flow rates and noise levels, respectively, for the newly developed fan. Compared with original model, the numerical results predicted a 3 dBA noise reduction; the measured reduction was 4 dBA.