Your best bet is to get the price down on what you have, not change processors that costs $$$ too.
$0.50 at 10k pieces 45,928 available? Good enough?
Otherwise to change processors. Presumably you have the source code for the PIC. Presumably it's C code.
You then hunt for your alternative. Making sure it is way cheaper. If you are serious about getting the price down you should be considering die, not not packaged ICs.
Find your cheap alternative. I would suggest looking at Zilog.
Then you have to "Port" the code. This is essentially moving it over to a new processor. It is hand done. It is a process that is greatly reduced if the original code is in C.
You'd work thru the I/O assignments for compatible hardware. This will include making sure you have the required support peripherals on the new platform. Like timers and an on-board oscillator, watchdog, if required, etc.
There are other aspects you need to watch too,(that could be show stoppers), but you probably know this if you are embarking on this endeavour.
Next you work thru the new platform's initialization requirements.
Then you prove the hardware.
Then you port the actual algorithm over.
Keith Cress
Flamin Systems, Inc.-