I CAN create a 1st level PC in 3rd edition in 10 minutes - this assumes I need something NOW, and I'm not goofing off with him, trying different concepts, tweaking every little thing, etc. If I'm tweaking a first level PC, anywhere from one hour to six hours. This applies, I find, until about 6th level or so.
Creating a high-level PC on the fly, let's say spellcaster, with or without PRC's, about an hour. If I'm enjoying the process, and have the time, then anywhere from six hours to 12 hours, in bits and pieces.
I have also found that PCGen and other char-gen software does not alter this amount of time - but what it DOES do is make my choices more optimized and sound, as I can compare options more quickly.