B3d - auto run on boot up - and not minimise!!?

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Knowing that you do kiosk-type apps, does the PC actually need to be useable as a Windows desktop as well?

If not (and depending on the version of Windows you're using), you could look at replacing explorer.exe with your program (ie. backup explorer.exe and replace it with your renamed app).

Alternatively, look at replacing the lower-level userinit.exe (which kicks off the whole desktop startup process) with your app's name in the Registry:

http://www.microsoft.com/technet/prodtechnol/windows2000serv/reskit/regentry/12330.mspx?mfr=true

This is of course a big modification to Windows and should only be tested on a machine you can easily fix/reinstall Windows on.

NB. I've never tried these options, so don't know what effect they'll have on services, networking, etc. I had an app run full-screen on startup with Windows ME alongside explorer (years ago) and had no problems, so never had to go any further...

Also, do you need Automatic Updates on this machine, or can it be done manually? (The obvious answer to the Windows Update thing is of course to disable it!)

Finally (assuming it's not being used as a desktop), disable everything you can via Autoruns or the simpler Startup Control Panel.