Mine is only 4 months old - I went in with a business card, the form filled out and then had my fingerprints taken and biometric scans taken (10 I believe). After that, my photo was taken and the card issued.

The last 2 times I tried to use it a YYZ, the machine was down and they do not let you cut to the front of the line, or any other shortcut - they make you wait like everyone else.