I had some spare time on my hands so I looked at the various CSC Plastic Card trackers and out of 27 cases, I calculated the length of time between "processing completed" status and "card ordered" status as reported by folks in these forums.
Here are the results:
Length of time: number of cases
same day: 1
one day: 8 <--my spouse (d) was in this category
two days: 5
three days: 9
four days: 2
five days: 1
eight days: 1
eleven days <-- in my case, I've been waiting eleven days (as of 09/07) for the next step, "card ordered", which seems way out of the ordinary.
There's nothing scientific about this at all because not everyone posts all their status milestones. But, from the ones that do, it is evident that 1-3 days is a reasonable length of time to expect your status to change from processing complete to card ordered.
If I do not get my card within 60 days, my attorney is planning to follow up, which presumably means calling the special 'attorney only' number at the CSC, and/or filing form G-371. I hope it doesn't come to that. We are traveling to England on September 11.
My wife(d) received all the right status updates and got her card on 09/03.