Results from the wasteland are mostly random. It is highly unlikely (but not impossible, as you have the proof in your game) that a level one dweller with wimpy stats comes across the most powerful weapon in the game in an hour of exploration. Your badass explorer with top stats and elite gear might not see that type of weapon after exploring for a week. This is how the RNG works.
Because of the randomness, there is no formula that guarantees that a dweller with X stats and Y gear explore for Z time period will come back with the best loot. What we do know is that having better SPECIAL, a higher level, and exploring for longer periods of time make it more likely that the dweller finds better gear, more caps, and earns more experience than another dweller with lower stats exploring for a shorter time period finds. You can see this at work by looking at the results after multiple explorations. Jericho may not be bringing back plasma weapons and fat men every time, but he should be reliably finding shotguns, rifles, and the like rather than rusty pistols.
The other factor that you haven't mentioned with Jericho is his level. Results in my game suggest that the level of the explorer may also factor into the quality of loot they find (although part of this is that lower level wanderers just can't survive very long). My lower level explorers tend to find mostly pistols, maybe
tl;dr
Yes it's possible. Congrats on your guided fat man. With repeated expeditions, the results should be more in line of better stats + more time = better loot, but there is no surefire way of getting the absolute best loot every time. Improve your SPECIAL, improve your level, send out for as long as possible, pray to the RNGods, and send more expeditions. Eventually you will get what you are looking for.
You got that message because you don't have enough storage capacity left in your vault to hold the items your dweller is bringing back from the field.
In this situation, you have two options:
Increase storage of your vault by building more storage rooms and/or by upgrading any existing storage rooms you already have.
Sell some of the items the dweller brought to you before you bring them back into the vault.
To determine how much more storage capacity you need, just click the dweller who has returned and look at the items they are carrying. The items with a red badge (background color) are the items that won't fit into the vault. The ones with a green badge will fit in the vault (see picture below).

As you buy more storage, you'll notice that more items will turn green. Once all items are green, you can hit the collect button and bring your dweller and all the items they are carrying inside the vault.
Although you can bring all the items inside your vault, you don't have to. You can also sell some less valuable items before the dweller gets in. You can select items for sale by clicking on them. Once you click on an item, they will turn into their value in caps. You'll also notice that more items turn green as you select them for sale. See picture below. You can revert the selection by clicking on them again.

I had exactly the same problem the first time I got a dweller back from a long trip: bought 3 storage rooms to fit all the stuff. That's probably because it's not very intuitive that you can sell the items before you tap one of them. But the extra storage ended up being useful anyway.
Best Answer
Not a defined way to remove them but when raiders/deathclaws attack, allow them to destroy one Mr Handy and move the one blocking you from removing rooms onto the top floor.
Unfortunately this will result in a permanent loss of one Mr Handy but there's really no other way.