Hey Brad,
I’m going to hazard an answer to your question by not actually answering your question (in the sense that I don’t know how helpful any particular numbers from me would be, since things are often so specific to project and platform requirements—I’ve never been in a situation where the cost for the rigs was especially high, but I’ve also never made games with dozens+ of simultaneous characters).
Some caveats: working on lots of small games, I’m generally in a position to take a fairly “whole-project” view. That being said, I tend to adopt the perspective that there are just a bunch of different places I can hit a ceiling (e.g., CPU/VFP [iPhone], RAM, build size, production capacity [cost, time, personnel, whatever], etc.). The natural consequence here is that for most of my work, the production capacity ceiling tends to be the first one I hit, with build size probably second most common. (These are both places where run-time rigs have saved me in one way or other, by the way!)
Those caveats out of the way, I can give a quick example with Touch KO 2.0 (which I recently killed). Retargeting for height differences and stance differences can be pretty trivially resolved with some 3-key additive animations for each attack (for each retarget required)—at least it’s close enough for government work, as the saying goes. However, moving the whole moveset to higher-fidelity mocap, increasing the number of unique sounds, etc. sometimes pushes too far for comfort against the memory ceiling on a first-gen device.
So, where am I freed up? Sounds are already as low of sample rate as they can be (without just being random barf garbage), and it’s faster to play back an uncompressed sound, so I can’t really budge on them without creating lots of boring silence. In this case, knowing which things are handled on different processors, and where I’m sitting on them, the cheap solution was to eliminate all the animations for the opposite stance (southpaw) and just apply a negative x-scale transformation to a character (by using a separate mesh with reflected vertices/normals, reverse winding order, swapped left/right bindposes, etc.). I know this probably doesn’t really sound like a “run-time rig,” but remember I’m basically just talking about transforming animation data when I use the phrase.
Anyhow, I hope that’s more helpful than just random rambling. Unfortunately, I don’t know anyone who’s done this on a large enough scale to offer you a more pointed answer (maybe they’re here on the forums).