I am starting to see where you’re difficulty is coming from.
I think the one point where you are tripping yourself up is:
God created an inherent flaw in man (im presuming that is man’s free will)
However, it is not an inherent flaw really, since, when used properly, it brings us closer to God. Now Man CHOOSES to be with God, instead of God just controlling man, (which as I said before would not be a loving relationship)
Man needs to make the choice to love God in return.
Now the heart of your question seems to revolve around God’s foreknowledge of all the suffering in the world.
Did God know that man would fall? yes
Did God realize that He would have to send Himself, His Son, in mortal form, to suffer on a cross for our sins? yes
Did God realize that this was a total injustice, for His innocent Son to die for all the wrongdoings of men? yes!
Why did He did do all of this, why did He even will any of it to happen, if it would just mean that people would suffer?
…Because (you guessed it) He loved us so totally and completely that He wanted to give us the chance, the CHANCE, to love Him in return.
I realize its difficult to see this if it is just taken rationally - then I would agree with you, it would have not been worth all the pain and effort.
If you are looking for another answer, I cannot tell you what it is. It is that God’s loves us.
“God created the universe in order to enter into a history of love with humankind. He created it so that love could exist. God created the universe in order to be able to become a human being and pour out his love upon us and to invite us to love him in return.” (Cardinal Ratzinger)
This is the hardest part, but it really is impossible to get any of this stuff unless you begin to see God’s love.
I can see a good heart behind you questions.If you are really pursuing the truth, then I can tell you that this question may not be answerable for you at the moment. I do not know what you’re personal beliefs are, but please dwell upon this with an open mind, and open heart, and if you feel the desire to please pray about this. Pray that you will find the truth behind your questions. I will be praying for you too.
The fact that you are asking these questions shows that you want to know more. However, do not expect to understand the infinite in a day (or a lifetime). These are big questions you are asking, so please be patient.