This sums up the problem I have with "Fly Solo" as well (documented in a different thread).
Yep.
my rebels made the mistake (without knowing it in advance of course) to open the door as their last action with Solo. Who got shot to death by everything that spawned after him and activated right then and there.
Correct me if I'm misunderstanding you, but,
If the Rebels open the door before Han escapes on his own, Han, the Stormtroopers, and the Officer all enter play with exhausted deployment cards. Neither Han nor the new Imperials may activate this round. In the following round, Rebels activate first and can try to get Han somewhere safe.