I solved this on a toughbook. The numlock was activating while windows started even with the regkey set to have it off.
(
http://support.microsoft.com/kb/154529/en-us)
All I had to do was restarting the PC waiting for windows to activate the numlock again during the shutdown process and then hitting the numlock once before windows was done.
Next time the Toughbook started the Numlock kept off!
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