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"Error Optimizing - The optimized sub sheets are not the same in the unique optimized sheet"

I've made several changes to settings to try to hit the printed reports correct for printing sheets to cut (plywood sheet layouts only, no holes or edging) - and after several settings changes - am getting the above error ( "Error Optimizing - The optimized sub sheets are not the same in the unique optimized sheet" ).

(the original problem I was trying to fix - is that the printouts are labeling each piece differently on each page instead of a standard label designation - so changed to smaller font and the piece names to be displayed and printed.   Also - Gives ALL piece names on each piece instead of JUST that piece name.  Now whenever I open the file - I get the error - as well as when I try to tap the "Optimize" button.

Layouts seem to change also - when I change labeling (not sure why - a design can span 4 sheets on one run, then 5 sheets the next - and no changes in piece sizes - but in the labeling).

Do I need to uninstall, and start with a clean install?  Or is there a known setting that I messed with that is causing this?

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