All. The. Time. I plot ut all of my novels in advance, but I also leave room for characters to grow and shape the plot on a micro level. Sometimes, the micro turns into macro, and a character is supposed to do something that turns out to be contrary to the personality that has emerged.
This happened in Black Hole Sun. The character Aine was supposed to be interesting to Durango, but the emergence of Vienne as a romantic element as well as Aine’s personality changing made that impossible. To fix it, I had to revise the plot and remove the corner all together.