Not my case, but I know someone (not on this forum) that I helped the app/renewal process, this was their timeline:

08/17/16 expiratoin
09/21/16 approved
09/22/16 Case tracker shows card is in production -- This did not even show up online until about yesterday, 09/29/16. Not sure if it's a status lag or process lag, it could be shipped as far as we know, or maybe it'll actually show completion status before shipping.

When I got mine in the mail the tracking # status update didn't happen until the day of receiving it physically, it's all fubar'd.