Here's what I took away from the novels Justin and Jesse wrote:
it's just simple math that If you put out product that turns faster and sells more volume, you can afford higher input costs.
Your idea I think revolves, a lot, around the idea the line will turn anything around quickly. I think the line's not suited for that right now.
I think Justin has a valid point. If you look back at the history of the line, there have been plenty of times (aka times when sales were good) where Hasbro has shown willingness to put more $ into a case knowing the sales would be there to recoup the costs. That is how we were able to get stuff like Hermi Odle, a Kybuck, Ewok 2-packs, Ephant Mon, etc. Or sometimes they lowered the prices knowing increased volume would make up for it ($4.50 ROTS figures in 2005)
But, I think that Jesse is right in that Justin's proposal only works if you get the increased sales to offset the higher input cost. And right now, with the low sales we're seeing (and you can take your pick for the reason - price, availability, figure selection, case pack, etc), Hasbro's not interested in taking the risk of putting more $ cost into a case and potentially not seeing a sales increase to recoup it because Star Wars is in the tank right now.
Somewhere amidst all the turmoil of the past two years (TPM flop, cancelled 3D releases, Disney/LFL changes), Hasbro made a decision to just ride out 2013/2014 with as little cost as possible. Just put the line on life support and wait for the LFL/Disney stuff to settle and Episode 7 to get here. So, here comes 3.75" collector cases with cheaper manufacturing raw material costs (smaller cardbacks, crappy plastic bubbles), less accessories, less paint masks, etc. And that's not even mentioning the $6 Legends or $10 Mission Series cost cutting moves.
I have no idea if that choice was right or wrong, because I have zero ideas of all the other factors involved in the decision. Did the Hasbro money guys cut their budget? Did Disney have some say in the direction they chose? Or did the 6" line cannibalized the 3.75" budget to some degree?