You can use the TestStand API to programmatically create global variables at runtime, thus ensuring their existence. For example, you could call Engine.Globals.SetValString("GlobalStringVariableName", PropOption_InsertIfMissing, "variable value")
Of course, if you need to test multiple UUTs in parallel, a single global is not sufficient. In that case you might consider adding the field you need to the UUT datatype in the process model. You could then access the field in your sequence via RunState.Root.Locals.UUT.YourNewField = YourNewValue.
If you also want your sequence to run without using a process model, you must check for the existence of the UUT before accessing it. You could use the expression function: PropertyExists("RunState.Root.Locals.UUT.YourNewFi
eld")