Data too long for column 'value' at row 1

I’ve been copying my production files into a development server at various times over the past year so that I can have a duplicate in case my production server crashes. I utilize a Search/Replace during the backup process. I’ve never experienced any issues until the last automatic WordPress update.

Now, after trying to run a Search and Replace, I get the following message: “Data too long for column ‘value’ at row 1”. I thought by installing the 4.1 WordPress update that maybe it would work some of the bugs out so I updated. I then copied my files, ran the Search/Replace and now I get the same message, only it’s now listed 3 times!

Prior to the 4.1 update a co-worker and I tried the following: We found quite a few tables in the SQL database with ‘value’ column fields in them. We opened the “Structure” tab and found column ‘name’ with row ‘value’ and noticed a column ‘type’. On the ‘value’ row we noticed ‘varchar(200)’ and changed it to 250. I re-copied files, SQL database and ran Search/Replace. Everything ran through without any errors. I’ve asked another web developer if changing the varchar on my Production side would cause major issues and she said not to do it. The update to WordPress 4.1 didn’t fix the problem so now I don’t know what to do.

Please advise!