Yes. Among those categories (seconds, overruns, and such), some sticks can possibly be sub-par for all the reasons you described. Isn't it a general understanding that these are 'premium' grade fallen into place of 'value' sticks at lower end market due to QC barrier? As a matter of fact it's an outstanding marketing strategy.
In one scenario when time permits you yourself alone with everything around you freeze for your "state of meditation" so to speak, you may celebrate it with premium stick such as Padron 1926 or your like. However in another scenario, when it's time to focus and zone into your demanding work, where you desire one occupied in your hand but may lack adequate attention to it, it'd makes better sense to let one of those value sticks entertain you organoleptically at the background of your primary focus. At such circumstance it is a little challenging to wrap one's head or senses around and fully appreciate the experience of premium stick. The difference in organoleptic quality is negligible. IMO.
In that regard, overruns/seconds haven't let me down so far. One important caveat though is to give it adequate aging time in your humidor for at least 3 weeks or more, in order to significantly enhance organoleptic quality. Generally speaking, I find better overall experience with one brand than the other. For instance, in my experience Oliva 90+ rated sun-grown overruns/seconds in value-pricing bundle come close or up to par with its regulars, Series V. (Yes! I have thoroughly enjoyed overruns and regulars back to back for weeks, and am not affiliated with Oliva)
Recently I started buying a wide variety of RP lines to support RP's involvement in war on cigars. Some lines are much more enjoyable than the other. So if I were to go down that path of seconds/overruns, then I'd like to invite the favorites to my humidor.
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