Prior work has demonstrated the potential to characterize surface and sub-surface pitting corrosion in both aircraft structures and tubing through the application of model-based inversion schemes to eddy current inspection data. However, there has been limited progress to transition such technologies to application due in part to questions about the robustness of the inverse method schemes to the expected variability with in-field NDE measurements. In this paper, a sensitivity analysis is performed for this case study problem to quantify the impact of potential sources for variation on the performance of NDE procedures incorporating inverse methods. Certain data processing steps, including careful feature extraction, background clutter removal and compensation for variation in the scan step size through the tubing, were found to be critical to achieve good estimates of the pit depth and diameter. Variance studied in model probe dimensions did not adversely affect inversion performance.