Use individual signup sheets. On the sheets should be the usual pertinent info:
Name
POP ID
Age
and some other sundry info that will help you make repeat customers:
Address
Phone #
Email Address
If this is your first POP Sanctioned Tourney, it's going to be slower as you're going to be handing out POP IDs like candy. Make sure that you spell their names correctly (not easy to correct right off the bat) and that the individual players get their password along with their POP ID. I suggest you either pool a bunch of TOs available POP IDs or email OP Support to have your quota of 20 raised. Otherwise you'll be running to someone's house to get more (after you've inputed the current list you have). If you can, get everyone a POP ID PRIOR to the event. This will speed things up some, but not much.
The software doesn't give us any speed advantages for new or existing players. When you put a new player in, it will be stored in the local players file (usually located at C:\Program Files\Tournament Manager\plaers.mdb) which is an Access file (I can't tell what version yet, but it's certainly not Access2003). SAVE THIS FILE AT ALL COSTS WHEN YOU REGISTER NEW PLAYERS. This file acts as the old text files did for local players. For later events, find the player in the pre-registered players window then double-click on them. This can get lengthy if you have a large number of players here and it doesn't sort very well. It seems to keep the order you entered people in, not using any other logical sorting method.
Hope all this helps!