When a new U.S. module factory came online, Strata’s supply chain and QA/QC teams found serious hidden defects before a single panel reached the site. By holding firm to our standards and working side by side with the manufacturer, we protected long‑term asset performance and kept a 212 MW solar project on schedule.
The Challenge: Factory QA/QC Without Shortcuts
Strata performed its standard QA/QC scope at the new factory, including in‑line production monitoring and detailed inspections. Our team reviewed 100% of the electroluminescence (EL) images for every PV module to spot micro‑cracks, cold soldering, and other issues that can cause degradation years after installation
Finding and Correcting Widespread Defects
As the factory ramped up, our inspections revealed widespread problems tied to equipment calibration and limited staff experience. Up to 60% of the modules were rejected early in the run. The manufacturer brought in technical experts from overseas, while Strata’s supply chain team and third‑party QA/QC consultants worked together to identify root causes and raise production quality.
Restoring Supply on Schedule
Through this joint effort, defect rates fell by 83%. At the same time, Strata secured additional volume from another factory to replace rejected modules, allowing the 212 MW plant to be built in just two months and meet the owner’s substantial completion date.
Result: Turning A Quality Risk into Advantage
By keeping defective modules out of the field, Strata protected the owner from long‑term performance losses of 4% or more. Rigorous QA/QC turned a serious quality risk into a reliability advantage, without sacrificing schedule.
