Clicarity โ€บ Solar Panel Assembly
๐Ÿ”† Industry ยท Solar Panel Assembly

When a module underperforms, can you see which cells went into it?

Which cell bins went into which module. Whether a laminator is drifting before the scrap shows it. Whether you could answer a warranty claim in ten years.

One assembler found 142 modules a month below rating. The largest cause was cell mismatch, which nobody could confirm because bins were never recorded per module.
Solar panel assembly plants, batch and test visibility live
As featured in PrintWeek India, April 2026 โ†—

Three assemblers. Each one binned carefully and never wrote down where the bins went.

01 Cells binned, and the mismatch that follows

Cells are sorted into bins by current. A module built from mismatched cells performs below its rating, and the loss is permanent.

Binning happens. Which bin went into which module is rarely recorded, so when flash test results disappoint there is nothing to look back at.

Modules below rated output, one month
Cell mismatch142 modules
Soldering / interconnect58 modules
Lamination defect37 modules
Glass or frame19 modules

Cell bin, string and operator attach to the module, so a flash result points back to what went in.

142 โ†’ 44 modulesbelow rating
Show me howFifteen minutes. We look at one module.
02 The laminator, and what it cost each time

Lamination is the operation that scraps a whole module rather than a component. Temperature, pressure and time all matter.

Cycles are set and trusted. Nobody records the parameters against the batch, so a drifting laminator is found by the failures rather than by the numbers.

Lamination scrap by machine, one month
Laminator 11.2%
Laminator 25.8%
Laminator 31.6%

Cycle parameters are recorded per batch, so a drift is visible before it becomes a month of scrap.

5.8% โ†’ 1.9%on the machine that was drifting
Find out howBring last month. Fifteen minutes.
03 Warranty, twenty-five years out

You warrant a module for decades. A claim arrives years later with a serial number.

You need the cell lot, the laminator, the flash result and the operator. If that was on paper, it is effectively gone, and you settle the claim without knowing whether anything else is affected.

Ability to answer a warranty claim
From paper recordsRarely
From partial systemsSometimes
Captured at each stageAlways

Everything attaches to the serial at the moment it is built and stays queryable for as long as you need it.

Any claim answerablewith the full build history
Show me howFifteen minutes. We look at one serial.

You warrant these for twenty-five years. The record needs to last as long as the promise.

Every batch. Every test. Every panel tracked.

This is how a print job moves through your business. Clicarity gives you live visibility at every phase, and flags delays before they become client calls.

01
Incoming & Preparation
4 stages
Solar Cell Receipt
Solar cells received, wattage, efficiency class, and lot number logged.
โœ“ Clicarity: Cell lot number recorded, full batch traceability from cell to panel
Cell Testing / Sorting
Cells tested on flash tester and sorted by efficiency class.
โœ“ Clicarity: Efficiency distribution logged, cell binning visible per lot
Cell Inspection
Visual inspection for cracks, chips, and cosmetic defects.
โš  โš  Common delay: high defect rate in incoming lot, production hold while supplier resolved
BOM Planning
EVA, backsheet, glass, frame, junction box, and sealant planned per batch.
โš  โš  Common delay: EVA or backsheet stock-out, assembly line stopped
02
String & Matrix Assembly
3 stages
Tabbing & Stringing
Cells tabbed and strung into series strings using stringer machine.
โœ“ Clicarity: String count per batch tracked, yield from cells to strings visible
Matrix Lay-Up
Strings laid up in glass-EVA-string-EVA-backsheet configuration.
โš  โš  Common delay: lay-up error. EVA crease or string misalignment causes lamination reject
Pre-Lamination Inspection
Matrix inspected before entering laminator.
โœ“ Clicarity: Pre-lam inspection logged, defective matrices removed before lamination
03
Lamination & Testing
4 stages
Lamination
Matrix laminated in vacuum laminator at controlled temperature and time.
โœ“ Clicarity: Lamination cycle parameters logged, deviation flagged immediately
Trimming
Laminated panel edges trimmed.
EL Testing
Electroluminescence test conducted, cracks and cell defects visible.
โœ“ Clicarity: EL result logged per panel, defect type and location recorded
Flash Test / I-V Curve
Panel power output measured on solar simulator.
โœ“ Clicarity: Wattage and efficiency logged, below-spec panels held
04
Framing & Dispatch
3 stages
Framing
Aluminium frame fitted on laminated panel.
โœ“ Clicarity: Framing done only after EL and flash test pass
Junction Box Fitting & IV Test
Junction box fitted, bypass diodes connected, final IV test conducted.
โœ“ Clicarity: Final test result per serial number, batch cannot dispatch without pass
Dispatch
Panels dispatched with test reports, EL images, and delivery challan.
โœ“ Clicarity: Full panel traceability from cell lot to dispatch preserved
""EL test failures were being found after framing, the most expensive point to rework. Now EL testing is done before framing. We catch defects when they are cheapest to fix.""
QU
Quality Head
Solar Panel Assembly Plant. Surat, Gujarat
As featured in PrintWeek India, April 2026. Vol 18, Issue 12 โ†— Also in Print Bulletin, May 2026. Pages 20โ€“21 โ†—

What improves in solar panel assembly businesses using Clicarity

โ†“ 60%
Rework cost from late EL failures
โ†‘ 35%
First-pass yield improvement
โ†“ 40%
Batch hold resolution time
5 days
To go live, full setup included

Questions from solar panel assembly businesses

How does Clicarity work for a printing business specifically?
Clicarity is configured around your specific print workflow, pre-press, printing, finishing, dispatch, in your terminology. Every job gets a unique ID and moves through your defined stages. You see live status, timestamps, and alerts when a job sits too long at every stage. The Clicarity team builds everything for you. You go live in 5 days.
Does it work for both offset and digital printing?
Yes. Clicarity works for any print process, offset, digital, wide format, screen printing, or a combination. The stages are configured around your actual workflow. If offset jobs go through plate making and digital jobs skip that stage, both can be tracked correctly under the same system.
Can it track material wastage at each stage?
Yes, with the Multi Licence. At every stage, your team logs quantity in and quantity out. Clicarity calculates the loss automatically. You see wastage by stage, by job, live, not at month-end when nothing can be done about it.
Will my press operators actually use it?
Yes. The update screen has two fields. Job ID and status. Under a minute. No training needed. GP Offset's entire team was using it from day one, including floor workers who had never used a software system before.

See every batch. Every test. Before the rework compounds.

Book a free demo. We'll map your solar panel assembly workflow live on the call.

No commitment Live in 5 days Annual licence Full setup included