Poor quality of commutator fusing process often causes quality issues like Resistance variation, Heat discoloration and Wire pressing enamel melting in armature. The quality measure of commutator fusing joint is estimated from variation in the resistance. Furthermore, four important process parameter, welding current (WC), spring load (SL) and cooler temperature (T) are considered as the factors influencing the quality of the joints. In order to develop an accurate relationship between the process inputs (4-component) and the response output (resistance variation), a linear regression model is deve1oped. ANOVA analysis is done by optimization software (MINITAB) to identify the significance of individual functional parameters and the developed model can be effectively used to predict the factors which affect the Quality.