You bring up some very insightful observations. If the aforementioned shocked reaction you describe is across the Hero Games senior staff, then it may be more indicative of a problem that is often observed in long-standing works such as novel series, television shows, films, and of course, game books. The problem is that the senior staff suffers some combination of being out-of-touch with what their fans/customers want, complacency to where they believe their own work requires no significant vetting, editing, or revision, or perhaps even an unwillingness to bring in new talent to explore new ideas.
Was Champions Complete necessary? Given how unwieldy the Hero System 6th Edition rules were and that the company was not printing more copies of Hero Basic 6th Edition, the answer is definitely yes. From a style and design perspective, could it have been better? Again, absolutely yes.
Was Fantasy Hero Complete necessary? Yes, since the intent seemed to be Hero Basic 6th Edition with a fantasy sourcebook as a stand-alone game. Did it have to be sub-par? No.
Am equally puzzled regarding the poor aesthetic design and layouts from Champions Complete and Fantasy Hero Complete, especially since previous source book editions for 5th and 6th were exceptionally well done, even with grayscale interior art. ?
At least Hero Games is making previous editions available on PDF for fans to select and use based on preference. ?