In order to truly develop a viable process you need to ramp it to some level in order to find the most obvious flaws. That is what people are referring to when they talk about "yield learning". You want your R&D team involved in that process early on, so I believe that doing this makes sense. It also makes economic sense, because you have invested in installing a process line to produce the wafers during development anyway. Knowing that it will take several months to get the next fab up and running on the new process why wouldn't you use that capacity to start building inventory for your initial launch while you wait for the HVM factory to come on line.
While Oregon has multiple fabs, they are in essence all really one big fab. While kind of hard to see exactly the red ovals in this picture show links connecting the clean rooms.
Just my opinion, but I feel like Intel's costs are higher because historically they didn't care. The goal was technology leadership and if that cost more, so be it. We live in a different world now and if Intel is going to be successful, they need to learn some hard lessons, including cost consciousness and developing robust processes with larger process windows.