Hello,
Really interesting project! First of all, I would like to take a look in the existing code. Maybe it's not protected and even if it is, there is a possibility to "crack" the password. All the desired functionality can be implemented from Excel-VBA. The only part that needs a code module in Outlook is the scheduled emails. VBA can handle Word documents and Outlook email messages without even a row of code in Word or Outlook.
My idea is to make the whole program an Excel add-on, with its own tab in Excel's ribbon, its "groups" and option icons, so that to access easily any part of it. The complete report could be a PDF file, in a predefined format (with your data, logo, ...), which can be attached to the email message.
A few words about me: I'm developing VBA code for more than 15 years and I'm a trainer for Excel, Word and VBA for 12+ years. As you can guess, I have created a plethora of programs of any kind and difficulty level, for both training purposes and business.
Looking forward to hear from you,
Kind regards,
chriskerpini