Format does not attempt to open a DOS device. At least not when it is half the way through. This message must come from another program running in the background. Format sets the DOS drive into "busy" state, so if another program attempts to access the partition while Format is still running, it fails. This usually happens when you format the partition you booted from. Or perhaps you have a virus checker running which regularly checks the root block. The root block of FastFileSystem is in the middle of the partition.
What happens if you click on "cancel" or on "retry" ? Does Format stop working or does it continue ?
Bye,
Thomas