Defect Analysis with Remedial Quality Controls in Manufacturing/Transport and Installation of Solar Photovoltaic Panels: A Case Study Driven Review

The economic viability of large‑scale photovoltaic (PV) deployment depends on the long‑term reliability of solar modules. Field surveys continue to reveal systematic defects introduced at the factory, during logistics, and on the construction site. This paper synthesises peer‑reviewed literature, international failure databases, and six recent case studies to (i) categorise dominant defect modes across the life‑cycle, (ii) quantify their impact on energy yield and levelised cost of electricity (LCOE), and (iii) propose a tiered quality‑control (QC) framework that integrates in‑line monitoring, shipment surveillance, and post‑installation acceptance testing. Results show that implementing the recommended remedial controls could avert up to 2.4 % annual revenue loss for utility‑scale assets.