Do I need to wait for a file to finish optimising before adding it to a playlist?
No. Even if the file is still being optimised, you can add it to the playlist as usual.
Why the file may appear on the TV before optimisation has finished
While the original file you uploaded is being optimised, Adeus Pendrive is also optimising the file for display on each TV.
This is why the file sometimes appears on the TV even before optimisation of the original file has finished.