I have got it working with AutoExec with a delay so it doesn't error on not having a document. However it only runs after the fact. If I export / upload, it hasn't run the macro yet. Whether it's held in normal or the .xml template. It runs on open only, if i suppress macros during open, the changes are not there, so whatever process does the uploading isn't triggering the macro. I'm guessing it really needs to be in that template that is locked out by password.
I found a Microsoft KB (286310) that states AutoExec wont run if Word is started by code, e.g.
Code:
Set oWord = CreateObject("Word.Application")
oWord.Visible = True
oWord.Documents.Open "C:\YourFile.doc"
which i suspect is how it works.
I'm now wondering if the guy on SupportNet that did manage it, only had it working on open / access and all users have macro settings low enough. Or they have not realised it's an issue.