Solar energy is one of the most promising renewable resources for building a sustainable future. However, the performance and reliability of solar photovoltaic (PV) modules can be significantly affected by certain manufacturing defects or issues during handling and installation. Key defects and their impacts include: • Micro-cracks: Often caused by mishandling or lamination stress. • Potential Induced Degradation (PID): Can reduce performance by up to 30% within 2–3 years. • Delamination: Moisture ingress may cause 8–10% long-term power loss. • Hot Spots: Localized heating can lead to 2–6% short-term yield loss. • Snail Trails: May reduce long-term efficiency by up to 2%. • Bubbles and voids in EVA: Moisture penetration can lower efficiency by 5–7% over time. • Glass breakage/edge chipping: Immediate rejection or field failure. Energy experts stress that ensuring proper quality control during manufacturing, transport, and installation is crucial to maximize module reliability and long-term performance. Such measures are key to advancing high-quality solar technologies, achieving maximum renewable energy output, and accelerating the global shift toward clean energy solutions.