I think I might have figured out my fail. There is no way to be sure but I think the exper buff from Inn is actually creating the problem. I had a character that I hadn't developed. She was logged out at a fishing spot as a Lv. 6 Fisher girl and nothing else. So I logged her in, completed the starter quest and put her in the Inn for a night. She was able to get Goldsmith to 10 on green bar exper 150% and I saw the same patterns of fail with her but as soon as her exper bonus expired she was rocking out 300+ quality Synth's. It's too early to be concise but I'd say the 50% amplification from exper is influencing more than just our experience gained. It's creating instability in how we craft as well.