You really should watch the video. Huang didn't blame 40nm.
"The parasitic, uhm, characterization from our foundries and the tools and the reality are simply not related. At all. We found that a major breakdown between the models, the tools and reality"
i.o.w. TSMC, your 40nm sucks.
The part about no communication between the departments is moot if they follow the design rules properly. Especially since they already had 40nm parts out and should know bloody well what would happen with their GF100 design.