Date: 201408
Local time of day: 0601-1200
Location: ZZZ.ARTCC, US
Flight conditions: VMC
Aircraft: A320
Operator: Air Carrier
Operating under: Part 121
Flight plan: IFR
Mission: Passenger
Flight phase: Cruise
Airspace: Class A ZZZ
ATC / advisory: Center ZZZ
Aircraft component: Cockpit Door
Component problem: Malfunctioning
Reporter organization: Air Carrier
Reporter function: Captain; Pilot Flying
Human factors: Human-Machine Interface; Confusion; Troubleshooting; Distraction; Communication Breakdown
Second reporter function: First Officer; Pilot Not Flying
Anomaly: Aircraft Equipment Problem Less Severe; Deviation - Altitude Crossing Restriction Not Met; Deviation / Discrepancy - Procedural Clearance; Flight Deck / Cabin / Aircraft Event Other / Unknown
Detector: Person Flight Attendant
When detected: In-flight
Result: Flight Crew Overcame Equipment Problem
Contributing factors: Aircraft; Human Factors
Primary problem: Aircraft

Narrative: [Shortly before top of descent] the First Officer called the Flight Attendant [to come forward so he could] go back and use the restroom. The A Flight Attendant came up and relieved the First Officer. When the First Officer was ready to return he knocked on the flight deck door. The A Flight Attendant looked through the peephole and attempted to open the cockpit door but was unable as it had become jammed somehow. [While] she attempted multiple times to pull the door open; the First Officer called and I advised him of the situation. While this was going on Center gave us a clearance to cross the intersection at FL330. We were currently at FL370 and the intersection was approximately 15 miles ahead of us. The First Officer and I remained in communication trying to resolve the stuck door and I was advising the Flight Attendant on what to do to attempt to free the door. I moved the cockpit door switch from normal to unlock numerous times although no faults were showing but this didn't help. Around this time Center called us. I had missed the descent point with the door jam distraction and they advised us to maintain FL370. I advised the Flight Attendant through coordination with the First Officer to unlatch the cockpit door escape panel and push it out to allow the First Officer to climb thru and back into the cockpit. The Flight Attendant was able to do so and the First Officer returned to the cockpit thru the panel. He then was able to forcibly open the cockpit door. The Flight Attendant exited the cockpit and the First Officer returned the panel to its normal position and returned the pins. He then resumed pilot not flying duties. I informed Center of what had happened which led to the distraction and missed crossing restriction. Nothing further was said from ATC. The flight was completed uneventfully; I entered a write up in the logbook and Maintenance was called out to fix the cockpit door. Maintenance found that all but one screw were missing from the door frame causing it to jam the door. Repairs were made and the logbook signed off; returning the aircraft to service. This was a rare occurrence and a significant distraction in the flight deck. In [retrospect]; I should have included ATC in what was happening on the flight deck and requested to remain at altitude.


Second narrative: After a several minutes of effort by the Flight Attendant; the cockpit escape hatch popped out of the door and onto the galley floor. I immediately crawled through the hatch; stood up on the flight deck; grabbed the flight deck door handle; turned it; and yanked on it with substantial force! It flexed and opened with these efforts. With the door now open; the Flight Attendant immediately exited the flight deck and I closed the door behind her. I then knelt down and called to the Flight Attendant in the galley to replace the escape hatch and apply pressure to it while I re-secured the pins. I secured the escape hatch and returned to my duty station.In my opinion; the crew handled this event appropriately and with professionalism. This very unusual situation created unusually intense risks and distractions. Any malfunction of the cockpit door is a distraction because such malfunction creates a grave threat to security of the flight deck. In this situation; the threat to security of the flight deck was compounded by an actual; current risk to flight safety in the form of a pilot locked out of the flight deck.


Synopsis: When the First Officer of an A320 returned to the flight deck after a break the Flight Attendant was unable to open the door to allow him to return.  During the extended time required to find a way for the pilot to gain admittance the Captain failed to comply with a descent clearance due to distractions directing potential solution suggestions to the Flight Attendant.