@Matt Venn, @Dinesh A, @jeffdi, my pre-check passes but, the tape-out fails at "Klayout Metal Minimum Clear Area Density" showing '1' DRC violation. It's because the "li1_ca_density is 0.3918" which is less than 0.4. My idea was to change the fd_Decap_12 to ef_decap_12. When I change this in my config.tcl and try to harden my macro, it halts at the LVS step infinitely but it generates the GDS with ef_decap_12. I'm afraid to use these GDS in the wrapper as the flow is not complete. When I try to replace the fd_decap_12 contents with ef_decap_12 in Klayout manually, the delete and replace options are disabled and I'm not able to delete or modify the contents. My questions: 1) Is it okay to use the GDS generated by OpenLane without the flow being complete? 2) Why would the options delete and replace be disabled in Klayout? 3) How do I fix the issue for a successful tape-out? Attached are snapshots and files related to this. Thank you for any help!

Normally li1_ca_density density indicate that your Marco design in small and you have allocated more DIE-AREA, Due to this tool added more Tap and De-Cap. Better you try reduce your user_proj_example die area. I see your user_proj_example logic is pretty small, not need current area of (0,0,900,600). You can try less size like (0,0,250,250)

Oh ok. That makes sense. I will change the area and redo it again. Thanks a lot!