Post-annealing of P3HT/C 60 -based plastic solar cells, composite ratio and, incorporation of a buffer layers at the ITO–polymer/fullerene composite interface and the polymer/fullerene composite–Al interface have shown significant improvement in the performance of the photovoltaic device, both in terms of open-circuit voltage and short-circuit current. The annealing temperature, time duration and P3HT/C 60 composite ratios have been optimized for the best performance of typical ITO/PEDOT:PSS/P3HT:C 60 /LiF/Al solar cell. The C 60 content is very crucial because it improves the photocurrent in the beginning but after a certain value it leads to decrease in absorption, thereby decreasing the photocurrent.