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I understand what you are saying but I'm not sure any of those facts are set in stone. You obviously cannot take a smaller defective panel and put it in a larger monitor bezel and call it good. But the other way around may be possible and a cheaper process than throwing the defective panels in the trash starting fresh every time.Yes, what you're saying is true for CPUs, GPUs, floppy drives etc but it would be quite different for LCD panels for at least three reasons that I can think of the top of my head.
1 Selling a monitor as having a 1440x900 resolution, but with the panel really being 1920x1080, a 1440x900 picture is going to either be shown smaller than the size of the panel for a 1:1 pixel mapping or will be stretched to fit and look awful
2 The monitor's panel driver electronics have to be designed for the display resolution and the higher the resolution, of course, the more expensive this gets
3 A defective 1080p panel cannot be sold as a lower resolution one since one would see visible defects on the screen, so there's no cost saving to manufacture
Drivers can be rewritten.
As far as visible defects, that would certainly depend on the extent of the defects. They would have to be minor. Certainly, using this tactic would not be possible with every defective panel coming off the line. But it could reduce the losses.
And for sure, there would have to be some modification and/or recoding process done. They could not just pop a different panel in and be done.
I am not saying you are wrong because I don't have any personal knowledge on the manufacturing process for monitors like I do with some other products. But I am saying with raw panels, "some" that don't pass the most stringent tests may be able to be cost-effectively modified to be re-purposed in lessor models rather than be a total loss.
That said, my reasoning really boils down to the fact I can come up with no other logical explanation for R-T-B's discovery - other than what I know to happen with all sorts of other products in many industries. I mean it is not likely it was just a matter of mislabeling and accidently dropping the wrong panel in for the very reasons you stated.