Recently I've been playing Diablo 3 and SWTOR some and it's pretty clear both game's single player difficulty was probably never actually tested by whoever designed it. I'm going to assume you're designing a game that is meant to be beaten in single player, so no Ninja Gaiden game where the purpose is to ensure nobody can actually beat the game.
I think the biggest way to design a good game is to set aside up to a week (40 hours) for a designer to attempt to beat his own single player game. If he can't do this fire him and redesign the game. Nobody on the Diablo 3 design team would've survived this if they have to do Inferno mode, and for a game like SWTOR some of those guys will need to be secretly doing overtime to ensure they don't get fired. Obviously you can skip some of the leveling up parts, though if you restrict to say only boss battles then you'd have to cut back the time limit appropriately. For example say 8 hours to beat all the boss encounters in a single character's story mode. You can easily use up your 8 hours on Lord Draggh or Darth Zash if you do not allow the character to be leveled beyond what's expected for the encounter.
I've come to realize a lot of real designers are just armchair developers like you and me, or you'd never see games that clearly makes no sense whatsoever. For example, Heroes of Might and Magic 4 on the impossible setting was actually impossible. You start the game and you immediately died on the first encounter and no amount of save/load can help you win because the first unit one shots your entire army and you cannot possibly build more units because you don't have a base yet. This isn't like Civilization series where on Deity you only have to load/save a stupid amount of times to get some totally improbably lucky start to win (though I doubt anyone actually play tested Deity mode either). You actually cannot win this at all. Now, there's nothing wrong with being an armchair developer since that's where ideas come from, but at some point the armchair guy has to be able to actually beat the game he designed. A game designer isn't a mathematician where you can merely be satisfied that a solution exist.
I think RIFT had the best single player design because the story mode bosses are actually sort of hard, as in they could actually beat you if you fight them straight up, but you can almost always beat them because there's always a trick involved. Although I don't play RIFT anymore, I think they really had a great team at developing everything. It's just for whatever reason the IP didn't seem to work out. I guess it's hard to beat Warcraft in fantasy and Star Wars in sci-fi.
I think the biggest way to design a good game is to set aside up to a week (40 hours) for a designer to attempt to beat his own single player game. If he can't do this fire him and redesign the game. Nobody on the Diablo 3 design team would've survived this if they have to do Inferno mode, and for a game like SWTOR some of those guys will need to be secretly doing overtime to ensure they don't get fired. Obviously you can skip some of the leveling up parts, though if you restrict to say only boss battles then you'd have to cut back the time limit appropriately. For example say 8 hours to beat all the boss encounters in a single character's story mode. You can easily use up your 8 hours on Lord Draggh or Darth Zash if you do not allow the character to be leveled beyond what's expected for the encounter.
I've come to realize a lot of real designers are just armchair developers like you and me, or you'd never see games that clearly makes no sense whatsoever. For example, Heroes of Might and Magic 4 on the impossible setting was actually impossible. You start the game and you immediately died on the first encounter and no amount of save/load can help you win because the first unit one shots your entire army and you cannot possibly build more units because you don't have a base yet. This isn't like Civilization series where on Deity you only have to load/save a stupid amount of times to get some totally improbably lucky start to win (though I doubt anyone actually play tested Deity mode either). You actually cannot win this at all. Now, there's nothing wrong with being an armchair developer since that's where ideas come from, but at some point the armchair guy has to be able to actually beat the game he designed. A game designer isn't a mathematician where you can merely be satisfied that a solution exist.
I think RIFT had the best single player design because the story mode bosses are actually sort of hard, as in they could actually beat you if you fight them straight up, but you can almost always beat them because there's always a trick involved. Although I don't play RIFT anymore, I think they really had a great team at developing everything. It's just for whatever reason the IP didn't seem to work out. I guess it's hard to beat Warcraft in fantasy and Star Wars in sci-fi.