About the faces -- I've been playing around with a tool cool FaceGen recently, and I was very impressed with how organic the faces turned out. By organic, I mean they don't look like they're made of polygons. All the faces I've made so far are composed of over 5000 polygons. I think 5000 polygons (not exactly, but you get what I mean) is the magic number for making faces look good. The newest FaceGen even allows you to take a photo and have them sculpt a face out of it. It was amazing. I even took an anime (3D anyway) character screen shot from a game and it was recreated brilliantly on FaceGen. I don't think FaceGen uses normal mapping in anyway. I'm sure you can use even less polygons to make a great looking face without having to use 5000 polygons.
Now here are some number for Rogue Squadron on the Gamecube.
"The X-Wing model is the original model used by Industrial Light and Magic (ILM), for special effects in the Stars Wars film and includes ILM's textures and shaders. The X-Wing alone is comprised of 30,000 polygons and the pilot has 4,000 polygons!"
This quote came straight from that Segatech website.
This is from EGM Number 144
"Director Tosti says the new Rogue Squadron flexes between 12,000 and 25,000 polys on its ships, 30,000 on terrains 13,000 on an AT-AT, and 3,000 on each Tie Fighter."
There's only one issue so far and that's the pilot's polygon count. In EGM, it says each pilot is about 8,000 compared to the 4,000 polys from Segatech. I don't know who's right and who's wrong.