Pardon me for chiming in again but Dedra has her radar on more Rebel activity than most of the other officers and even before she had personal knowledge of Andor possibly being complicit, the bolo was already out on him...what, they have all the technology in the universe to spread his mug throughout the whole galaxy and build a Death Star but Alcatraz has no facial recognition system to be able to find him? I mean, he changed his name, big deal...people do it all the time. Everything to me seems very well tidy and coincidental to try to make everything work( like , oh an escape pod just sitting there seated for two...the same amount of people as the owners) and make sense but it doesn't. As soon as that point is brought to the surface all of a sudden everyone comes out of the woodwork that has theories why they wrote it that way that makes Mike Zeroh's theories sound believable. If we have to stretch and surmise everything to explain any inconsistencies then maybe we should chalk it up to "they made a mistake"...That is more believable and acceptable to me as answers.
There's nothing wrong with conjuring rationalizations to explain apparent inconsistencies so long as they are
plausible within the context of the established setting. "Plausibility" is usually the point of contention. A rationale need not be dismissed simply because it wasn't witnessed so as long as the proposal is consistent with the setting or situation. e.g. If Syril walks through level 1313 and suddenly finds his cash missing it is not unreasonable to presume that he was pickpocketed. It is plausible even if you didn't actually see it happen.
Here is the setting of Andor. Remember that Aldhani was such an inconceivable affront to the Empire (by design) the Empire was provoked to instantly go into tyranny mode (which is what Luthen was banking on) in the form of PORD.
PORD was implemented literally overnight. As a result, in an instant, across
an entire galaxy, prison sentences were multiplied, prison releases were cancelled, incarceration of a larger body of "the usual suspects" sought any excuses for arrest (e.g. Cassian was loitering while adding false charges), the legal system was abbreviated to where the accused lost all rights and was instantly sentenced. The load of cases that just got dumped on the system was astronomical.
We saw this depicted in the crowded processing center where Cassian went after his arrest. He was even expecting some form of appeal process but, instead, was simply sentenced and ushered off to incarceration. You get the sense of a system that is overloaded and struggling to keep up with the sheer volume of cases.
So, under normal circumstances the Empire might have run his profile to bio-ID him, then cross reference through some galactic database. However, the writer took great lengths to show us these are not normal circumstances and that we are looking at systems operating in crisis mode. I can see how they might have to abbreviate the process because of it. Seemingly a person can go from citizen to suspect to inmate in less than 24 hours.
Presumably the Empire would eventually ramp up construction for bigger/better processing facilities but that doesn't happen overnight. I would think that higher security prisons would be prioritized to get the bulk of resources and support up front before the other prisons do. Given the nature of Cassian's crimes I think we can assume that Narkina 5 isn't maximum security. We see it is understaffed and probably some correctional officers may have been reallocated to other higher priority prisons.
In response to PORD the Empire is probably ramping up the facilities, equipment and staffing but, until then, local jurisdictions will do what they can to keep things running and prevent backlog. And the resources would appropriately go towards the higher-level prisons. And until the infrastructure is built, a lot of inmates simply aren't going to get a comprehensive vetting. In a lower level-type prison that's probably a safe temporary tradeoff, as far as the Empire is concerned.
In a vast galaxy of thousands of worlds spanning light-years it is tough enough trying to communicate, much less synchronize the database for millions of criminals on a routine basis. The same system under stress is going to be even worse. I'm just making a case for why I think it's plausible that Cassian wasn't ID'd. It's still your prerogative to think it's contrived.