So here's how it went for us.
Ordered it online not too long before our trip, and got it perhaps a bit later than some were getting it, but still in good time.
The voucher for the lanyard and card were taped to the outside of the CD case. I put that into my travel bag as soon as possible, to make sure to bring it.
When we got to the parks, I went into the photo shop on Main Street. The CM who greeted me saw the voucher and, it turned out, started getting the lanyard ready for me. However, the CM he guided me to did NOT know what was going on. The first guy had to help him through the process, but since he had things at the ready, it didn't take as long as it could have done.
Going out of order here, I really recommend NOT using the lanyard they give you OR find a Guest Services/Relations spot that has tape. The tape goes around the metal clasp so that the cards won't come off of the clasp thing.
The ride photos were VERY simple. Get the photo number, get in line, give them the card, get the receipt for the upload, go on your way! All but the TOT picture got onto the account without a problem (and as I mentioned, the TOT picture was found by the photopass people when I used their form), but I was very glad to get the receipts. Now that I think about it, it was the receipt that reminded me I was supposed to have a TOT photo!
The restaurant photos were a GREAT deal. We did Surf's Up and Goofy's Kitchen. You get the prints in their glossy folders, and I find that to be really fun.
Those photos are ONLY the ones taken at the front of the restaurant (or just inside for Surf's Up); you'll still need to take pictures on your own with the roaming characters inside.
We used a few normal PP cards as well. I wasn't at Pirate's League with DH and DS, and they put it on a normal card. Now, at WDW, I read that PL gives print packages like at the restaurants! Either DLR doesn't have that (since PL is just a temporary thing) or we missed out on it b/c I didn't know about it and we weren't using a + card. I can't remember why we had the other card or two.
We took regular PP pictures as well, and even got an enhancement on one of them (Frankenweenie sitting on the ground as we point and stare), and it was all fine.
We got home, I uploaded them, got the TOT picture on there, did the borders and saved them in various sizes.
Now, as I was going through this process (which took something like a week, total, because I'm slow *but* we didn't have THAT many pictures), I got a total of THREE emails offering up special bonus downloads, which ended up being all of the ride photos. It was pretty neat, to be able to get them (at least the 4x6 versions of them) immediately.
And they also sent me emails about the bonus photos of things like the "fab five" in front of the castle, etc. Those automatically got added to my account.
Then I opened the CD sent originally, found the code to order, and ordered it.