by european law the card should be issued within 6 months, but it doesn't matter how long it takes, as long as your wife is living with you.
the family permit is only for entering the UK, if she leaves the UK and doesnt have a residence card she would have to apply for another family permit.
once shes is in the ~UK shes doesnt need any visa, but like i said it mkaes sense to get a residence card
