As stated in the original posting, the circuit "basically works" but some units would not "come up" under certain circumstances. The design is a two board system where one board has the K22F acting as the primary controller (user interface, data repository, etc.) and the other board has a PIC18 processor acting as the real-time, low power data interface.
By eliminating various possibilities, like RST rise times, etc., we narrowed the problem down to a few possibilities, one of them being latch-up. Since the external voltage was controlled by the PIC18, we delayed the application of that voltage until it was known that the K22F was fully operational. Now, although testing is not yet complete, the system appears to power up correctly all the time.
Your suggestion of a current limiting resistor may have taken care of this problem, but the circuit is in production and making the firmware change was easier.
Thanks for your help,
Dave