You want a keyboard with a solid warranty to cover yourself as even the replacements share this problem almost as bad as the ones these laptops generally came with. Since my warranty expired I moved to a model of waiting until the keyboard controller shows obvious failure signs that are causing it to fail with how expensive it would be to fix over a key failure, especially if you don't use it a lot or at all. The keyboard is a consumable part with how often it fails. I'm on my 5th keyboard with my E6540 (4 replacements/1 factory) so it's a common fault. The keyboards on these machines seem to have a reliability problem that perists as the machines age even though current/new owners replace them as it happens and I'd bet many of them are replacements. I don’t know the supplier in the link and there may be other similar suppliers online (I didn’t look after I found this one) if you wish to pursue this option. It may be possible to just repair the individual key. Has any liquid been spilled onto the keyboard in the area around the key? If it works when using a USB keyboard then most probably it is a hardware problem with the number lock key itself. If the setting is already enabled, try using a USB keyboard connected to the laptop, just to verify that the number lock function is working and that it is not a software problem. Scroll to p.58-59 to find the information regarding the Number Lock setting.
Take note of the function of the Esc key if you have to alter the setting and want to save the change.
Scroll to the top of p.52 which shows which keys on the keyboard to use to navigate through the BIOS menus. Here’s a link to the owner manual for your laptop. Navigate to the Table.9 POST Behavior menu and check the setting. To get into BIOS, start the laptop and press F2 when the Dell logo is on the screen. Check in BIOS to see if the Number Lock enable setting is set to Enable.
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