I'm going to beat this horse to death, I'm certain, but I'll say it again...
At max on Saturday, we had maybe 4 people working at the pre-reg desk at a time trying to get people in some sembelance of alphabetical order...
I guess I don't get how this is a difficult process, as it's done year after year at other conventions.
If the primary problem is people, you can always borrow staff from other departments temporarily. Asking for volunteers from a line of 1000 wouldn't be too hard also, especially if you offered air conditioning in return. I didn't see any staff fishing for volunteers, though!
Next year, I would happily have been a volunteer for 2-3 hours on Saturday but it's sort of a chicken-and-egg problem. How do I volunteer when I'm not registered?
I think the fundamental problem is that you pre-print the badges, so it becomes a problem of finding people's names in a stack. And that stack is being accessed by multiple people at the same time. And directing people to the correct stack is hard.
One way that might have worked with pre-printing would have been to have N tables set up with the badges in order for people to self-serve. Obviously, you'd have to monitor things and control flow. But then, they would go to somebody to match their badge to their ID. The number off the badge would be crossed off a list and they would get a holder. Probably it would work better to have one person manage the list and the person doing the checking would simply tell that one person which numbers to check off.
In the worst case scenario (somebody steals a badge), you have the master list.
As another suggestion, Anime Boston uses an off-the-shelf solution that's used at countless conventions, for the very purpose of printing badges on demand. I'm sure it's not cheap, but should be rentable.
By the way: Queue and data processing is actually what I do for a living. Though what I usually deal with are computer messages, I'm a systems "architect" for maximizing performance design. Most throughput problems are due to accessing identical bits of data from multiple processes, it's called mutual exclusion. Here's some light reading:
http://en.wikipedia.org/wiki/Amdahl's_law