Ideas for Exercises/Simulations for Lean Training?

Ken Theriot,
Check out the dice game that Goldratt uses (rolling dice and moving material from one perso to the next). It takes about 45 minutes to 1 hour and you can drive the idea of bottlenecks and variation reduction in one exercise.
Just my opinion.
Good luck

In a nutshell, you set up a facotry consisting of tables arranged rather haphazardly with the baseline run exhibiting horrendous, yet realistic conditions encountered in real factories. (i.e. excess inventory, inept management, unbalanced lines, rigid wasteful processing,etc…)
You run the round, collect/analyze the data (COPQ) and discuss potential improvements(Line0balancing, footprint reduction, Muda reduction/elimination, Kan bans, etc…)
Run round two, debrief and run a final round, all the while using DMAIC/PDCA cycles. 

They are proprietary, but you hit on something w/ the legos.   Both exercises use legos, duplos or bristle blocks.   Center the exercise around the production of an item comprised of multiple sub-assembly builds.   Bombardier put a really good exercise together to take into account, transactional environments.   Their product was a service.
I’d suggest designing your own based on 3-ten minute rounds with “teachable moments” designed into the breaks between rounds.   It doesn’t matter what you have them build, in fact, the sillier, the better.
The take-aways I focus on  are:
data collection
DMAIC/9-step model/PDCA
FMEA
Facilitation/team building
SPACER
MSA
NEM
DOE
COPQ
Lean concepts

I would appreciate if i can get the dice game information too. Thanks.

Ken,
If you don’t mind spending a little money, check out The Lean Man.  He sells wooden car assembly kits for Lean training.  I have no affiliation with him, but have seen these products in action. 
I have participated in various Lego exercises, and would report that they must be carefully orchestrated and choreographed to provide proper learning.  They can range from simple to very complex.
One of the more impressive learning Lean demos involves a simple college logo being written on index cards and stapled.  Again, can be simple or more complex.  The best thing is that it’s inexpensive and quick.
Hope this helps!

If someone has a full set of old Allied Signal Aggie Boat training material, I would be very interested.    I have a lot of the Blocks,  and a lot of the material,  but not the full set.