Date: 201501
Flight conditions: VMC
Aircraft: A319
Operator: Air Carrier
Operating under: Part 121
Flight plan: IFR
Mission: Passenger
Flight phase: Cruise
Aircraft component: Interior Door
Component problem: Malfunctioning
Reporter organization: Air Carrier
Reporter function: Pilot Not Flying; First Officer
Human factors: Training / Qualification
Second reporter function: Dispatcher
Anomaly: Aircraft Equipment Problem Less Severe; Deviation / Discrepancy - Procedural Security
Detector: Person Flight Crew
When detected: Pre-flight
Result: Flight Crew Became Reoriented; General Maintenance Action
Contributing factors: Human Factors; Procedure; Aircraft
Primary problem: Human Factors

Narrative: When the flight crew arrived at the aircraft; cockpit door was observed to be locked and APU was running (most likely done by the tug crew prior to crew show).  Inputting the emergency access code would not open door and no lights or tones were seen/heard; indicating that the emergency cockpit door access panel was not working properly.  Maintenance was advised and two mechanics responded.  Eventually; to access the cockpit; they forced an automatic APU shutdown which depowered the door and allowed cockpit access.  However; when they deferred the emergency access panel in accordance with their maintenance procedures; they used the wrong procedure and disconnected wires/plugs behind the 'center console door panel' instead of the overhead 'cockpit door control panel' and subsequently pulled and saftied the PAX MON CB.  Both pilots checked the Maintenance Release and MEL and followed listed procedures; pushing back and taking off with no unusual events.In flight; while opening the door to receive meals; it was found that the cockpit door strikers were completely depowered and the door had been unlocked since maintenance had released the aircraft and could be opened from the cabin by forcefully pushing on it.  The door was immediately barricaded with crew bags and the center jumpseat was slid into position to keep the door in the closed position and to prevent cockpit access. The Captain notified Maintenance Control; Dispatch and the Duty Manager; and after they sent the proper MEL procedures the flight crew realized that Maintenance had used the wrong procedure to defer the malfunction which resulted in an illegal dispatch.  The proper MEL pilot items were complied with and the PAX MON CB was pushed in at Maintenance Control's direction.  The door locks energized and the door was checked to be secure. Maintenance was thoroughly debriefed on the ground; as was the oncoming crew.


Second narrative: The flight crew arrived at the aircraft to find the cockpit door locked. The keypad would not unlock the door. Maintenance personnel were eventually able to get the door open. maintenance personnel applied MEL Reference number X (Cockpit Access Keypad Inop) in the log book. At XA33z while the acft was in flight dispatch received a message that was relayed to Maintenance Control that maintenance had pulled and collared circuit breaker; which removed all power to the door latch. The door was not able to be secured. Maintenance control confirmed that circuit breaker should not have been pulled and/or collared and advised the crew to reset the breaker which the flight crew did and the door was secured. In a phone patch between the flight and maintenance control; it was determined that the MEL was improperly executed and notated in the log book. The crew also failed to confirm door secure procedures in the before pushback checklist. The airplane will be grounded in EWR on arrival pending a maintenance inspection.


Synopsis: A319 flight crew discovers upon arrival at the aircraft that the cockpit door is locked and that it cannot be unlocked using the keypad. Maintenance is called and defers the lock using the wrong MEL procedure which renders the door locking mechanism inoperative. This is not discovered by the crew until enroute.