Trollkiller, The other crafting thread Crafting Fake % Success has plenty of information. The community is very detailed in the thread and made many suggestions.
The crafting is not bugged, it is just extremely punishing, which failing the crafting process should be. My initial complaint was satisfied by Mike. After even more testing the numbers tend to balance out. There are going to be outliers like in any probabilistic system. The key question is does the system have a confidence interval that is acceptable to EHG. It means we the player base have to adjust or figure out better ways to improve the stats we find.